Komatsu - pc360lc 10.he - Sm.sen05619 03.Jp - Ocrbmd

SEN05619-03
HYDRAULIC PC360LC -10

EXCAVATOR
SERIAL NUMBERS 70001 and up
SHOP MANUAL
HYDRAULIC EXCAVATOR
PC360LC-10
Model Serial Number
PC360LC-10 70001 and up
00 Index and foreword

1 00 Index and foreword
PC360LC-10 00-1
Index
Index (ALL-0310-001-A-00-A)
00 Index and foreword ....................................................................................................................... 00-1
Index ......................................................................................................................................... 00-2
Foreword, safety and general information ................................................................................... 00-14
Important safety notice ....................................................................................................... 00-14
How to read the shop manual.............................................................................................. 00-21
Explanation of terms for maintenance standard .................................................................... 00-23
Handling equipment of fuel system devices .......................................................................... 00-25
Handling of intake system parts........................................................................................... 00-26
Handling of hydraulic equipment.......................................................................................... 00-27
Method of disconnecting and connecting of push-pull type coupler ......................................... 00-29
Handling of electrical equipment.......................................................................................... 00-32
How to read electric wire code............................................................................................. 00-40
Precautions when performing operation ............................................................................... 00-43
Practical use of KOMTRAX ................................................................................................. 00-48
Standard tightening torque table.......................................................................................... 00-49
List of abbreviation ............................................................................................................. 00-55
Conversion table ................................................................................................................ 00-60
01 Specification................................................................................................................................. 01-1
Table of contents ........................................................................................................................ 01-2
Specifications............................................................................................................................. 01-3
Specification drawing ........................................................................................................... 01-3
Working range drawings ....................................................................................................... 01-4
Specifications ...................................................................................................................... 01-5
Weight table ........................................................................................................................ 01-8
Table of fuel, coolant and lubricants ..................................................................................... 01-10
10 Structure and function ................................................................................................................... 10-1
Engine and cooling system .......................................................................................................... 10-3
Engine related parts ............................................................................................................. 10-3
KVGT.................................................................................................................................. 10-5
EGR system piping drawing ................................................................................................ 10-12
EGR system circuit diagram ................................................................................................ 10-14
EGR valve......................................................................................................................... 10-16
EGR cooler........................................................................................................................ 10-18
KCCV layout drawing ......................................................................................................... 10-19
KCCV ventilator ................................................................................................................. 10-22
KDPF................................................................................................................................ 10-24
Cooling system .................................................................................................................. 10-28
Power train............................................................................................................................... 10-30
Power train ........................................................................................................................ 10-30
Swing circle ....................................................................................................................... 10-31
Swing machinery ............................................................................................................... 10-32
Final drive ......................................................................................................................... 10-34
Undercarriage and frame........................................................................................................... 10-36
Track frame and idler cushion ............................................................................................. 10-36
Hydraulic system ...................................................................................................................... 10-38
Hydraulic component layout ................................................................................................ 10-38
Valve control...................................................................................................................... 10-40
Hydraulic tank.................................................................................................................... 10-42
CLSS ................................................................................................................................ 10-44
Main pump ........................................................................................................................ 10-49
Control valve ..................................................................................................................... 10-74
Swing motor .................................................................................................................... 10-130
Travel motor .................................................................................................................... 10-141
PPC valve ....................................................................................................................... 10-156
Solenoid valve ................................................................................................................. 10-177
Attachment circuit selector valve ....................................................................................... 10-181
00-2 PC360LC-10
Index
Center swivel joint ............................................................................................................ 10-184

Accumulator .................................................................................................................... 10-186
Work equipment ..................................................................................................................... 10-187
Work equipment............................................................................................................... 10-187
Cab and its attachments .......................................................................................................... 10-190
Cab mount and cab tipping stopper ................................................................................... 10-190
ROPS cab ....................................................................................................................... 10-191
Electrical system .................................................................................................................... 10-192
Electrical control system ................................................................................................... 10-192
Machine monitor system ................................................................................................... 10-240
KOMTRAX system ........................................................................................................... 10-259
Sensor ............................................................................................................................ 10-262
20 Standard value tables.................................................................................................................... 20-1
Standard service value table........................................................................................................ 20-3
Standard value table for engine related parts .......................................................................... 20-3
Standard value table for machine .......................................................................................... 20-5
30 Testing and adjusting .................................................................................................................... 30-1
Related information on testing and adjusting ................................................................................. 30-3
Tools for testing and adjusting ............................................................................................... 30-3
Sketch of tools for testing and adjusting ................................................................................. 30-7
Testing engine speed ........................................................................................................... 30-9
Testing boost pressure ....................................................................................................... 30-10
Testing exhaust gas color ................................................................................................... 30-13
Testing and adjusting valve clearance .................................................................................. 30-15
Testing compression pressure............................................................................................. 30-19
Testing blowby pressure ..................................................................................................... 30-27
Testing engine oil pressure ................................................................................................. 30-29
Testing EGR valve and KVGT oil pressures .......................................................................... 30-30
Testing fuel pressure .......................................................................................................... 30-31
Testing fuel discharge, return and leakage............................................................................ 30-38
Bleeding air from fuel system .............................................................................................. 30-44
Testing fuel circuit for leakage ............................................................................................. 30-45
Handling cylinder cutout mode operation.............................................................................. 30-46
Handling no-injection cranking operation.............................................................................. 30-47
Checking and adjusting air conditioner compressor belt tension ............................................. 30-48
Replacing fan belt .............................................................................................................. 30-49
Replacing alternator belt ..................................................................................................... 30-50
Power train............................................................................................................................... 30-51
Testing swing circle bearing clearance ................................................................................. 30-51
Testing and adjusting track tension ...................................................................................... 30-52
Releasing remaining pressure from hydraulic circuit .............................................................. 30-53
Testing and adjusting oil pressure in work equipment, swing, and travel circuits....................... 30-54
Testing oil pressure of control circuit .................................................................................... 30-60
Testing and adjusting oil pressure in pump PC control circuit.................................................. 30-62
Testing and adjusting oil pressure in pump LS control circuit .................................................. 30-67
Testing outlet pressure of solenoid valve .............................................................................. 30-76
Testing PPC valve output pressure ...................................................................................... 30-80
Adjusting play of work equipment and swing PPC valves....................................................... 30-82
Testing pump swash plate sensor ........................................................................................ 30-83
Isolating the parts causing hydraulic drift in work equipment................................................... 30-84
Testing oil leakage ............................................................................................................. 30-86
Bleeding air from hydraulic circuit ........................................................................................ 30-88
Cab and its attachments ............................................................................................................ 30-91
Checking cab tipping stopper .............................................................................................. 30-91
PC360LC-10 00-3
Index
Adjusting mirrors ................................................................................................................ 30-92

Electrical system ...................................................................................................................... 30-95
Special functions of machine monitor ................................................................................... 30-95
Adjusting rearview camera angle ....................................................................................... 30-161
Handling voltage circuit of engine controller........................................................................ 30-163
Handling battery disconnect switch .................................................................................... 30-164
Testing diodes ................................................................................................................. 30-165
Pm clinic ................................................................................................................................ 30-166
Pm clinic service .............................................................................................................. 30-166
40 Troubleshooting............................................................................................................................ 40-1
Related information on troubleshooting......................................................................................... 40-9
Troubleshooting points ......................................................................................................... 40-9
Sequence of events in troubleshooting................................................................................. 40-11
Checks before troubleshooting ............................................................................................ 40-13
Inspection procedure before troubleshooting ........................................................................ 40-15
Preparation work for troubleshooting of electrical system....................................................... 40-34
Classification and procedure for troubleshooting ................................................................... 40-41
Symptom and troubleshooting numbers ............................................................................... 40-44
Information in troubleshooting table ..................................................................................... 40-47
Troubleshooting method for open circuit in wiring harness of pressure sensor system .............. 40-49
Connector list and layout .................................................................................................... 40-51
Connector contact identification........................................................................................... 40-62
T-branch box and T-branch adapter table ........................................................................... 40-100
Fuse location table ........................................................................................................... 40-105
Preparation of dummy temperature sensor (for KDOC and KDPF temperature
sensors)............................................................................................................. 40-107
Preparation of short circuit electrical connector (for failure codes [CA1883] and
[CA3135]) .......................................................................................................... 40-108
Precautions for KDPF (KCSF and KDOC) Cleaning and Replacement ................................. 40-109
Failure codes table........................................................................................................... 40-112
Troubleshooting by failure code (Display of code) ...................................................................... 40-121
Failure code [879AKA] A/C Inner Sensor Open Circuit ........................................................ 40-121
Failure code [879AKB] A/C Inner Sensor Short Circuit......................................................... 40-122
Failure code [879BKA] A/C Outer Sensor Open Circuit........................................................ 40-123
Failure code [879BKB] A/C Outer Sensor Short Circuit ........................................................ 40-124
Failure code [879CKA] Ventilating Sensor Open Circuit ....................................................... 40-125
Failure code [879CKB] Ventilating Sensor Short Circuit ....................................................... 40-126
Failure code [879DKZ] Sunlight Sensor Open Or Short Circuit ............................................. 40-127
Failure code [879EMC] Ventilation Damper Abnormality ...................................................... 40-128
Failure code [879FMC] Air Mix Damper Abnormality ........................................................... 40-129
Failure code [879GKX] Refrigerant Abnormality .................................................................. 40-130
Failure code [989L00] Engine Controller Lock Caution 1...................................................... 40-131
Failure code [989M00] Engine Controller Lock Caution 2..................................................... 40-132
Failure code [989N00] Engine Controller Lock Caution 3 ..................................................... 40-133
Failure code [A1U0N3] HC Desorb Request 1 .................................................................... 40-134
Failure code [AA10NX] Air Cleaner Clogging ...................................................................... 40-138
Failure code [AB00KE] Charge Voltage Low....................................................................... 40-140
Failure code [B@BAZG] Eng Oil Press Low ....................................................................... 40-142
Failure code [B@BAZK] Eng Oil Level Low ........................................................................ 40-143
Failure code [B@BCNS] Eng Water Overheat .................................................................... 40-144
Failure code [B@BCZK] Eng Water Level Low ................................................................... 40-145
Failure code [B@HANS] Hyd Oil Overheat ......................................................................... 40-147
Failure code [CA115] Eng Ne and Bkup Speed Sens Error .................................................. 40-148
Failure code [CA122] Chg Air Press Sensor High Error ....................................................... 40-149
Failure code [CA123] Chg Air Press Sensor Low Error ........................................................ 40-151
Failure code [CA131] Throttle Sensor High Error................................................................. 40-153
Failure code [CA132] Throttle Sensor Low Error ................................................................. 40-155
00-4 PC360LC-10
Index
Failure code [CA144] Coolant Temp Sens High Error .......................................................... 40-157
Failure code [CA145] Coolant Temp Sens Low Error ........................................................... 40-159
Failure code [CA153] Chg Air Temp Sensor High Error ........................................................ 40-161
Failure code [CA154] Chg Air Temp Sensor Low Error......................................................... 40-163
Failure code [CA187] Sensor 2 Supply Volt Low Error ......................................................... 40-165
Failure code [CA221] Ambient Press Sensor High Error ...................................................... 40-167
Failure code [CA222] Ambient Press Sensor Low Error ....................................................... 40-169
Failure code [CA227] Sensor 2 Supply Volt High Error......................................................... 40-171
Failure code [CA234] Eng Overspeed ................................................................................ 40-172
Failure code [CA238] Ne Speed Sensor Supply Volt Error ................................................... 40-173
Failure code [CA239] Ne Speed Sens Supply Volt High Error............................................... 40-174
Failure code [CA271] IMV/PCV1 Short Error ...................................................................... 40-175
Failure code [CA272] IMV/PCV1 Open Error ...................................................................... 40-177
Failure code [CA281] Pump Press Balance Error ................................................................ 40-179
Failure code [CA295] Ambient Pressure Sensor In Range Error ........................................... 40-180
Failure code [CA322] Inj #1(L#1) Open/Short Error ............................................................. 40-181
Failure code [CA343] ECM Critical Internal Failure.............................................................. 40-193
Failure code [CA351] Injectors Drive Circuit Error ............................................................... 40-194
Failure code [CA356] Mass Air Flow Sensor High Error ....................................................... 40-197
Failure code [CA357] Mass Air Flow Sensor Low Error ........................................................ 40-199
Failure code [CA428] Water in Fuel Sensor High Error ........................................................ 40-202
Failure code [CA429] Water in Fuel Sensor Low Error ......................................................... 40-204
Failure code [CA435] Eng Oil Press Sw Error ..................................................................... 40-206
Failure code [CA441] Battery Voltage Low Error ................................................................. 40-207
Failure code [CA442] Battery Voltage High Error................................................................. 40-209
Failure code [CA449] Rail Press Very High Error................................................................. 40-210
Failure code [CA451] Rail Press Sensor High Error............................................................. 40-212
Failure code [CA452] Rail Press Sensor Low Error ............................................................. 40-214
Failure code [CA488] Chg Air Temp High Torque Derate...................................................... 40-216
Failure code [CA515] Rail Press Sens Sup Volt High Error .................................................. 40-217
Failure code [CA516] Rail Press Sens Sup Volt Low Error ................................................... 40-219
Failure code [CA553] Rail Press High Error ........................................................................ 40-221
Failure code [CA555] Crankcase Press High Error 2 ........................................................... 40-222
Failure code [CA559] Rail Pump Press Low Error ............................................................... 40-224
Failure code [CA595] Turbo Speed High Error 2 ................................................................. 40-228
Failure code [CA687] Turbo Speed Low Error ..................................................................... 40-229
Failure code [CA689] Eng Ne Speed Sensor Error .............................................................. 40-231
Failure code [CA691] Intake Air Temp Sens High Error ........................................................ 40-235
Failure code [CA692] Intake Air Temp Sens Low Error......................................................... 40-237
Failure code [CA697] ECM Internal Temp Sensor High Error................................................ 40-239
Failure code [CA698] ECM Int Temp Sensor Low Error........................................................ 40-240
Failure code [CA731] Eng Bkup Speed Sens Phase Error ................................................... 40-241
Failure code [CA778] Eng Bkup Speed Sensor Error........................................................... 40-243
Failure code [CA1117] Persistent Data Lost Error................................................................ 40-248
Failure code [CA1664] KDOC Malfunction.......................................................................... 40-249
Failure code [CA1691] Regeneration Ineffective ................................................................. 40-251
Failure code [CA1695] Sens 5 Supply Volt High Error.......................................................... 40-254
Failure code [CA1696] Sens 5 Supply Volt Low Error .......................................................... 40-255
Failure code [CA1843] Crankcase Press Sens High Error.................................................... 40-257
Failure code [CA1844] Crankcase Press Sens Low Error .................................................... 40-259
Failure code [CA1879] KDPF Delta P Sensor High Error ..................................................... 40-261
PC360LC-10 00-5
Index
Failure code [CA1881] KDPF Delta P Sensor Low Error ...................................................... 40-263
Failure code [CA1883] KDPF Delta P Sens In Range Error.................................................. 40-265
Failure code [CA1921] KDPF Soot Load High Error 1.......................................................... 40-268
Failure code [CA1942] Crankcase Press Sens In Range Error ............................................. 40-276
Failure code [CA1993] KDPF Delta Pressure Low Error ...................................................... 40-277
Failure code [CA2185] Throt Sens Sup Volt High Error ........................................................ 40-280
Failure code [CA2186] Throt Sens Sup Volt Low Error......................................................... 40-282
Failure code [CA2249] Rail Press Very Low Error ............................................................... 40-284
Failure code [CA2265] Fuel Feed Pump Open Error............................................................ 40-285
Failure code [CA2266] Fuel Feed Pump Short Error ............................................................ 40-287
Failure code [CA2271] EGR Valve Pos Sens High Error ...................................................... 40-289
Failure code [CA2272] EGR Valve Pos Sens Low Error ....................................................... 40-291
Failure code [CA2288] Turbo Speed High Error 1................................................................ 40-294
Failure code [CA2311] IMV Solenoid Error ......................................................................... 40-295
Failure code [CA2349] EGR Valve Solenoid Open Error ...................................................... 40-296
Failure code [CA2353] EGR Valve Solenoid Short Error ...................................................... 40-298
Failure code [CA2357] EGR Valve Servo Error ................................................................... 40-300
Failure code [CA2373] Exhaust Manifold Press Sens High error........................................... 40-301
Failure code [CA2374] Exhaust Manifold Press Sens Low error ........................................... 40-303
Failure code [CA2375] EGR Orifice Temp Sens High Error .................................................. 40-305
Failure code [CA2376] EGR Orifice Temp Sens Low Error ................................................... 40-307
Failure code [CA2381] KVGT Pos Sens High Error ............................................................. 40-309
Failure code [CA2382] KVGT Pos Sens Low Error .............................................................. 40-311
Failure code [CA2383] KVGT Solenoid Open Error ............................................................. 40-314
Failure code [CA2386] KVGT Solenoid Short Error ............................................................. 40-316
Failure code [CA2387] KVGT Servo Error .......................................................................... 40-318
Failure code [CA2554] Exh Manifold Press Sens In Range Error .......................................... 40-319
Failure code [CA2555] Grid Htr Relay Open Circuit Error ..................................................... 40-320
Failure code [CA2556] Grid Htr Relay Short Circuit Error ..................................................... 40-322
Failure code [CA2637] KDOC Face Plugging ..................................................................... 40-324
Failure code [CA2639] Manual Stationary Regeneration Request......................................... 40-326
Failure code [CA2961] EGR Orifice Temp High Error 1 ........................................................ 40-329
Failure code [CA2973] Chg Air Press Sensor In Range Error ............................................... 40-330
Failure code [CA3133] KDPF Outlet Press Sens High Error ................................................. 40-331
Failure code [CA3134] KDPF Outlet Press Sens Low Error.................................................. 40-333
Failure code [CA3135] KDPF Outlet Press Sens In Range Error .......................................... 40-335
Failure code [CA3251] KDOC Inlet Temp High Error............................................................ 40-339
Failure code [CA3253] KDOC Temp Error - Non Regeneration............................................. 40-342
Failure code [CA3254] KDOC Outlet Temp High Error 1 ...................................................... 40-345
Failure code [CA3255] KDPF Temp Error - Non Regeneration.............................................. 40-348
Failure code [CA3256] KDPF Outlet Temp High Error 1 ....................................................... 40-351
Failure code [CA3311] KDOC Outlet Temp High Error 2....................................................... 40-354
Failure code [CA3313] KDOC Inlet Temp Sensor Low Error ................................................. 40-360
Failure code [CA3314] KDOC Inlet Temp Sens High Error ................................................... 40-363
Failure code [CA3315] KDOC Inlet Temp Sens In Range Error............................................. 40-367
Failure code [CA3316] KDOC Outlet Temp Sens Low Error ................................................. 40-371
Failure code [CA3317] KDOC Outlet Temp Sens High Error................................................. 40-374
Failure code [CA3318] KDOC Outlet Temp Sens In Range Error .......................................... 40-378
Failure code [CA3319] KDPF Outlet Temp Sens High Error ................................................. 40-382
Failure code [CA3321] KDPF Outlet Temp Sens Low Error .................................................. 40-386
Failure code [CA3322] KDPF Outlet Temp Sens In Range Error........................................... 40-389
Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error ........................................ 40-393
Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error ......................................... 40-395
Failure code [CA3741] Rail Press Valve Trip Error............................................................... 40-397
Failure code [D110KB] Battery Relay Drive S/C .................................................................. 40-398
Failure code [D19JKZ] Personal Code Relay Abnormality.................................................... 40-400
Failure code [D811MC] KOMTRAX Error............................................................................ 40-403
00-6 PC360LC-10
Index
Failure code [D862KA] GPS Antenna Open Circuit ............................................................. 40-404

Failure code [D8ALKA] System Operating Lamp Disconnection (KOMTRAX)........................ 40-405
Failure code [D8ALKB] System Operating Lamp Short Circuit (KOMTRAX) .......................... 40-407
Failure code [D8AQKR] CAN2 Discon (KOMTRAX) ............................................................ 40-408
Failure code [DA20MC] Pump Controller Malfunction .......................................................... 40-409
Failure code [DA22KK] Pump Solenoid Power Low Error..................................................... 40-410
Failure code [DA25KP] 5V Sensor1 Power Abnormality ...................................................... 40-412
Failure code [DA29KQ] Model Selection Abnormality .......................................................... 40-415
Failure code [DA2LKA] System Operating Lamp Disconnection (Pump Con) ........................ 40-417
Failure code [DA2LKB] System Operating Lamp Short Circuit (Pump Con) ........................... 40-419
Failure code [DA2QKR] CAN2 Discon ( Pump Con) ............................................................ 40-420
Failure code [DA2RKR] CAN1 Discon ( Pump Con) ............................................................ 40-423
Failure code [DAF0MB] Monitor ROM Abnormality.............................................................. 40-424
Failure code [DAF0MC] Monitor Error ................................................................................ 40-425
Failure code [DAF8KB] Camera Power Supply Short Circuit ................................................ 40-426
Failure code [DAF9KQ] Model Selection Abnormality .......................................................... 40-428
Failure code [DAFGMC] GPS Module Error........................................................................ 40-429
Failure code [DAFLKA] Operating Lamp Open Circuit(Monitor) ............................................ 40-430
Failure code [DAFLKB] System Operating Lamp Short Circuit (Monitor)................................ 40-432
Failure code [DAFQKR] CAN2 Discon (Monitor) ................................................................. 40-433
Failure code [DAZ9KQ] AC Model Selection Abnormality .................................................... 40-434
Failure code [DAZQKR] CAN2 Discon (AC)........................................................................ 40-435
Failure code [DB2QKR] CAN2 Discon (Engine Con) ........................................................... 40-440
Failure code [DB2RKR] CAN1 Discon (Engine Con) ........................................................... 40-445
Failure code [DGH2KB] Hyd Oil Sensor Short Circuit .......................................................... 40-449
Failure code [DHA4KA] Air Cleaner Clogging Sensor Open Circuit ....................................... 40-451
Failure code [DHPAMA] Pump Press Sensor Abnormality ................................................... 40-453
Failure code [DHPBMA] R Pump Press Sensor Abnormality ................................................ 40-456
Failure code [DHS3MA] Arm IN PPC Sen. Abnormality ....................................................... 40-459
Failure code [DHS4MA] Bucket CURL PPC Press Sensor Abnormality ................................ 40-461
Failure code [DHS8MA] Boom RAISE PPC Press Sensor Abnormality ................................. 40-464
Failure code [DHS9MA] Boom LOWER Press Sensor Abnormality....................................... 40-467
Failure code [DHSAMA] Swing RH PPC Press Sensor Abnomality....................................... 40-470
Failure code [DHSBMA] Swing LH PPC Press Sensor Abnomality ....................................... 40-473
Failure code [DHSCMA] Arm OUT PPC Press Sensor Abnormality ...................................... 40-476
Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality ................................ 40-479
Failure code [DHSFMA] Travel FW L PPC Press Sensor Abnormality................................... 40-482
Failure code [DHSGMA] Travel FW R PPC Press Sensor Abnormality ................................. 40-485
Failure code [DHSHMA] Travel BW L PPC Press Sensor Abnormality .................................. 40-488
Failure code [DHSJMA] Travel BW R PPC Press Sensor Abnormality .................................. 40-491
Failure code [DKR0MA] F pump S/P sensor Abnormality..................................................... 40-494
Failure code [DKR1MA] R pump S/P sensor Abnormality .................................................... 40-496
Failure code [DR21KX] Camera 2 Picture Rev. Drive Abnormality ........................................ 40-498
Failure code [DV20KB] Travel Alarm Short Circuit............................................................... 40-502
Failure code [DW43KA] Travel Speed Sol Open Circuit ....................................................... 40-504
Failure code [DW43KB] Travel Speed Sol Short Circuit ....................................................... 40-506
Failure code [DW45KA] swing holding brake Sol Open Circuit ............................................. 40-508
Failure code [DW45KB] Swing Brake Sol Short Circuit ........................................................ 40-511
Failure code [DW91KA] Travel Junction Sol Open Circuit .................................................... 40-514
Failure code [DW91KB] Travel Junction Sol Short Circuit..................................................... 40-516
Failure code [DWA2KA] Attachment Sol Open Circuit.......................................................... 40-518
Failure code [DWA2KB] Attachment Sol Short Circuit.......................................................... 40-520
Failure code [DWK0KA] 2-stage Relief Sol Open Circuit ...................................................... 40-522
Failure code [DWK0KB] 2-stage Relief Sol Short Circuit ...................................................... 40-524
Failure code [DWK2KA] Variable Back Pressure Sol Open Circuit ........................................ 40-526
Failure code [DWK2KB] Variable Back Pressure Sol Short Circuit ........................................ 40-528
Failure code [DWK8KA] Swing C/O Solenoid Open Circuit .................................................. 40-530
Failure code [DWK8KB] Swing C/O Solenoid Short Circuit................................................... 40-532
PC360LC-10 00-7
Index
Failure code [DXA8KA] PC-EPC (F) Sol Open Circuit.......................................................... 40-534

Failure code [DXA8KB] PC-EPC (F) Sol Short Circuit.......................................................... 40-536
Failure code [DXA9KA] PC-EPC (R) Sol Open Circuit ......................................................... 40-538
Failure code [DXA9KB] PC-EPC (R) Sol Short Circuit ......................................................... 40-540
Failure code [DXE0KA] LS-EPC Sol Open Circuit ............................................................... 40-542
Failure code [DXE0KB] LS-EPC Sol Short Circuit ............................................................... 40-544
Failure code [DXE4KA] Service Current EPC Disc. ............................................................. 40-546
Failure code [DXE4KB] Service Current EPC S/C ............................................................... 40-547
Failure code [DXE5KA] Merge-divider Main Sol Open Circuit ............................................... 40-548
Failure code [DXE5KB] Merge-divider Main Sol Short Circuit ............................................... 40-550
Failure code [DXE6KA] Merge-divider LS Sol Open Circuit .................................................. 40-552
Failure code [DXE6KB] Merge-divider LS Sol Short Circuit .................................................. 40-554
Failure code [DY20KA] Wiper Working Abnormality ............................................................ 40-556
Failure code [DY20MA] Wiper Parking Abnormality............................................................. 40-558
Failure code [DY2CKB] Washer Drive Short Circuit ............................................................. 40-560
Failure code [DY2DKB] Wiper Drive (For) Short .................................................................. 40-562
Failure code [DY2EKB] Wiper Drive (Rev) Short ................................................................. 40-564
Troubleshooting of electrical system (E-mode) .......................................................................... 40-566
E-1 Engine does not start (Engine does not crank) .............................................................. 40-566
E-2 Manual preheating does not work ................................................................................ 40-572
E-3 Automatic preheating system does not work................................................................. 40-575
E-4 While preheating is working, preheating monitor does not light up .................................. 40-577
E-5 When starting switch is turned to ON position, machine monitor displays nothing............. 40-579
E-6 While starting switch is turned to ON position (with engine stopped), engine oil level
monitor lights up in yellow.................................................................................... 40-582
E-7 While starting switch is turned to ON position (with engine stopped), radiator coolant level
E-8 Engine coolant temperature monitor lights up in white while engine is running ................. 40-584
E-9 Hydraulic oil temperature monitor lights up in white while engine is running ..................... 40-585
E-10 Charge level monitor lights up in red while engine is running ........................................ 40-586
E-11 Fuel level monitor lights up in red while engine is running............................................. 40-587
E-12 Air cleaner clogging monitor lights up in yellow while engine is running ......................... 40-588
E-13 Engine coolant temperature monitor lights up in red while engine is running .................. 40-589
E-14 Hydraulic oil temperature monitor lights up in red while engine is running ...................... 40-590
E-15 Engine oil pressure monitor lights up in red while engine is running .............................. 40-591
E-16 Fuel gauge display does not move from minimum or maximum .................................... 40-592
E-17 Display of fuel gauge differs from actual fuel level ....................................................... 40-593
E-18 Engine coolant temperature gauge display does not move from minimum or
maximum ........................................................................................................... 40-594
E-19 Display of engine coolant temperature gauge differs from actual coolant
temperature ....................................................................................................... 40-595
E-20 Hydraulic oil temperature gauge display does not move from minimum or
maximum ........................................................................................................... 40-596
E-21 Display of hydraulic oil temperature gauge differs from actual oil temperature ................ 40-598
E-22 Machine monitor does not display partially.................................................................. 40-599
E-23 Function switch does not operate............................................................................... 40-600
E-24 Automatic warm-up system does not work (in cold weather)......................................... 40-601
E-25 When auto-decelerator switch is operated, auto-decelerator monitor does not light up or
does not go off.................................................................................................... 40-602
E-26 Auto-decelerator is not operated or canceled with lever ............................................... 40-603
E-27 When working mode switch is operated, working mode selection screen is not
displayed ........................................................................................................... 40-604
E-28 When working mode is changed, setting of engine and hydraulic pump is not
changed............................................................................................................. 40-605
E-29 When travel speed switch is operated, travel speed monitor does not change ............... 40-606
E-30 When travel speed selection is changed, actual travel speed does not change .............. 40-607
E-31 Alarm buzzer cannot be canceled .............................................................................. 40-608
E-32 When starting switch is turned OFF, service meter is not displayed ............................... 40-609
E-33 Machine monitor cannot be set in service mode .......................................................... 40-610
00-8 PC360LC-10
Index
E-34 Any of work equipment, swing and travel does not work............................................... 40-611
E-35 Any of work equipment, swing and travel cannot be locked .......................................... 40-613
E-36 Upper structure does not swing while swing brake cancel switch is set to CANCEL
position .............................................................................................................. 40-615
E-37 Swing brake does not operate while swing brake cancel switch is set to NORMAL
position .............................................................................................................. 40-617
E-38 One-touch power maximizing function does not work properly or pilot monitor is not
displayed ........................................................................................................... 40-619
E-39 One-touch power maximizing function cannot be canceled .......................................... 40-621
E-40 Alarm does not sound during travel ............................................................................ 40-622
E-41 Alarm does not stop sounding while machine is stopped.............................................. 40-624
E-42 Horn does not sound ................................................................................................ 40-625
E-43 Horn does not stop sounding..................................................................................... 40-627
E-44 When wiper switch is operated, wiper monitor does not light up or go off ....................... 40-628
E-45 Wiper does not operate when wiper switch is operated ................................................ 40-629
E-46 When window washer switch is operated, window washer does not operate.................. 40-631
E-47 Boom LOWER indicator is not displayed properly with monitoring function .................... 40-632
E-48 Arm OUT indicator is not displayed properly with monitoring function ............................ 40-633
E-49 Arm IN indicator is not displayed properly with monitoring function................................ 40-634
E-50 Boom RAISE indicator is not displayed properly with monitoring function ...................... 40-635
E-51 Bucket CURL indicator is not displayed properly with monitoring function...................... 40-636
E-52 Bucket DUMP indicator is not displayed properly with monitoring function ..................... 40-637
E-53 Swing indication is not displayed properly with monitoring function ............................... 40-638
E-54 Travel indication is not displayed properly with monitoring function ............................... 40-639
E-55 Service indication is not displayed properly with monitoring function ............................. 40-640
E-56 Attachment circuit is not switched .............................................................................. 40-642
E-57 KOMTRAX system does not operate properly............................................................. 40-643
E-58 Machine push-up function is not canceled .................................................................. 40-644
E-59 Machine push-up function does not work.................................................................... 40-646
Troubleshooting of hydraulic and mechanical system (H-mode) .................................................. 40-647
Information described in troubleshooting table (H-mode) ..................................................... 40-647
List of Failure Mode and Cause ......................................................................................... 40-648
H-1 All of work equipment, swing and travel operation lacks speed or power ......................... 40-653
H-2 Engine speed lowers significantly or engine stalls ......................................................... 40-657
H-3 Any of work equipment, swing and travel does not work ................................................ 40-660
H-4 Unusual sound is heard from around hydraulic pump .................................................... 40-661
H-5 Fine control performance or response is poor　............................................................ 40-662
H-6 Speed or power of boom is low.................................................................................... 40-664
H-7 Speed or power of arm is low ...................................................................................... 40-668
H-8 Speed or power of bucket is low .................................................................................. 40-673
H-9 Work equipment does not move in single operation....................................................... 40-677
H-10 Hydraulic drift of boom is large .................................................................................. 40-678
H-11 Hydraulic drift of arm is large ..................................................................................... 40-679
H-12 Hydraulic drift of bucket is large ................................................................................. 40-681
H-13 Time lag of work equipment is large ........................................................................... 40-682
H-14 When part of work equipment is relieved singly, other parts of work equipment
move ................................................................................................................. 40-684
H-15 One-touch power maximizing function does not work .................................................. 40-685
H-16 Machine push up function does not work.................................................................... 40-686
H-17 In combined operation of work equipment, equipment having heavier load moves
slower................................................................................................................ 40-687
H-18 In combined operations of swing and boom RAISE, boom rising speed is low................ 40-688
H-19 In combined operations of swing and travel, travel speed drops largely......................... 40-689
H-20 Machine does not travel straight ................................................................................ 40-690
H-21 Travel speed is too low ............................................................................................. 40-693
H-22 Machine is hard to steer or travel power is low ............................................................ 40-695
H-23 Travel speed does not change, or travel speed is too low or high.................................. 40-698
H-24 One of tracks does not run ........................................................................................ 40-699
H-25 Upper structure does not swing in both right and left directions..................................... 40-701
PC360LC-10 00-9
Index
H-26 Upper structure does not swing in only one direction. .................................................. 40-702
H-27 Swing acceleration or swing speed is low in both directions (right and left) .................... 40-703
H-28 Swing acceleration performance is poor or swing speed is slow in only one
direction............................................................................................................. 40-704
H-29 Upper structure overruns remarkably when it stops swinging in both directions (right and
left).................................................................................................................... 40-705
H-30 Upper structure overruns excessively when it stops swinging in only one
direction............................................................................................................. 40-706
H-31 Shock is large when upper structure stops swinging.................................................... 40-707
H-32 Large unusual noise is heard when upper structure stops swinging .............................. 40-708
H-33 When swing holding brake is applied, hydraulic drift of swing is large............................ 40-709
H-34 When swing holding brake is released, hydraulic drift of swing is large.......................... 40-710
H-35 When additional attachment is installed, attachment circuit is not switched.................... 40-711
H-36 Oil flow in attachment circuit cannot be controlled ....................................................... 40-712
Troubleshooting of engine (S-mode)......................................................................................... 40-713
Information contained in troubleshooting table (S mode)...................................................... 40-713
S-1 Engine does not crank when starting switch is turned to START position......................... 40-714
S-2 The engine cranks but exhaust smoke does not come out ............................................. 40-715
S-3 Fuel is being injected but engine does not start (incomplete combustion: engine cranks but
does not start) .................................................................................................... 40-716
S-4 Startability is poor....................................................................................................... 40-717
S-5 Engine does not pick up smoothly ............................................................................... 40-719
S-6 Engine stops during operation ..................................................................................... 40-721
S-7 Engine runs rough or is unstable ................................................................................. 40-723
S-8 Engine lacks power .................................................................................................... 40-724
S-9 KDPF gets clogged in a short time ............................................................................... 40-726
S-10 Engine oil consumption is excessive .......................................................................... 40-728
S-11 Engine oil becomes contaminated early...................................................................... 40-729
S-12 Fuel consumption is excessive .................................................................................. 40-730
S-13 Oil is in coolant (or coolant spurts or coolant level goes down)...................................... 40-731
S-14 Oil pressure drops .................................................................................................... 40-732
S-15 Fuel mixes into engine oil.......................................................................................... 40-733
S-16 Water mixes into engine oil (milky) ............................................................................. 40-734
S-17 Coolant temperature rises too high (overheating) ........................................................ 40-735
S-18 Unusual noise is heard ............................................................................................. 40-736
S-19 Vibration is excessive ............................................................................................... 40-737
S-20 Air cannot be bled from fuel circuit ............................................................................. 40-738
S-21 Frequent active regeneration..................................................................................... 40-739
S-22 Active regeneration takes time................................................................................... 40-740
S-23 White smoke is exhausted during active regeneration ................................................. 40-741
50 Disassembly and assembly ........................................................................................................... 50-1
Related information on disassembly and assembly ........................................................................ 50-4
How to read this manual ....................................................................................................... 50-4
Coating materials list ............................................................................................................ 50-6
Special tools list ................................................................................................................. 50-10
Sketches of special tools .................................................................................................... 50-15
Engine and cooling system ........................................................................................................ 50-18
Removal and installation of supply pump assembly............................................................... 50-18
Removal and installation of injector assembly....................................................................... 50-28
Removal and installation of cylinder head assembly.............................................................. 50-44
Removal and installation of radiator assembly ...................................................................... 50-66
Removal and installation of hydraulic oil cooler assembly ...................................................... 50-69
Removal and installation of aftercooler assembly .................................................................. 50-72
Removal and installation of engine and main pump assembly ................................................ 50-73
Removal and installation of engine front seal ........................................................................ 50-85
Removal and installation of engine rear seal......................................................................... 50-90
Removal and installation of fuel tank assembly ..................................................................... 50-97
Removal and installation of engine hood assembly ............................................................... 50-99
00-10 PC360LC-10
Index
Removal and installation of KDPF assembly....................................................................... 50-102

Disassembly and assembly of KDPF ................................................................................. 50-109
Removal and installation of KCCV assembly ...................................................................... 50-118
Removal and installation of air cleaner assembly ................................................................ 50-120
Removal and installation of air conditioner compressor assembly......................................... 50-122
Removal and installation of air conditioner condenser assembly .......................................... 50-124
Power train system ................................................................................................................. 50-126
Removal and installation of travel motor and final drive assembly ......................................... 50-126
Disassembly and assembly of final drive ............................................................................ 50-127
Removal and installation of swing motor and swing machinery assembly .............................. 50-136
Disassembly and assembly of swing machinery.................................................................. 50-138
Removal and installation of swing circle assembly .............................................................. 50-145
Undercarriage and frame......................................................................................................... 50-146
Separation and connection of track shoe assembly ............................................................. 50-146
Removal and installation of sprocket.................................................................................. 50-149
Removal and installation of idler and idler cushion assembly ............................................... 50-150
Disassembly and assembly of idler .................................................................................... 50-151
Disassembly and assembly of idler cushion........................................................................ 50-154
Disassembly and assembly of track roller ........................................................................... 50-156
Disassembly and assembly of carrier roller......................................................................... 50-158
Removal and installation of revolving frame assembly ......................................................... 50-161
Removal and installation of counterweight assembly ........................................................... 50-163
Hydraulic system .................................................................................................................... 50-167
Removal and installation of center swivel joint assembly ..................................................... 50-167
Disassembly and assembly of center swivel joint ................................................................ 50-169
Removal and installation of hydraulic tank assembly ........................................................... 50-170
Removal and installation of main pump assembly ............................................................... 50-173
Removal and installation of control valve assembly ............................................................. 50-177
Disassembly and assembly of control valve........................................................................ 50-183
Disassembly and assembly of work equipment PPC valve................................................... 50-188
Disassembly and assembly of travel PPC valve.................................................................. 50-190
Work equipment ..................................................................................................................... 50-192
Removal and installation of bucket assembly...................................................................... 50-192
Removal and installation of arm assembly.......................................................................... 50-193
Removal and installation of work equipment assembly ........................................................ 50-195
Disassembly and assembly of work equipment cylinder....................................................... 50-198
Removal and installation of operator's cab assembly........................................................... 50-204
Removal and installation of operator cab glass (adhered glass) ........................................... 50-209
Removal and installation of front window assembly ............................................................. 50-219
Removal and installation of floor frame assembly................................................................ 50-225
Removal and installation of air conditioner unit assembly..................................................... 50-231
Removal and installation of operator's seat......................................................................... 50-235
Removal and installation of seat belt .................................................................................. 50-237
Removal and installation of front wiper assembly ................................................................ 50-239
Removal and installation of engine controller assembly ....................................................... 50-246
Removal and installation of pump controller assembly......................................................... 50-249
Removal and installation of machine monitor assembly ....................................................... 50-252
Removal and installation of pump swash plate sensor ......................................................... 50-254
Removal and installation of mass air flow and temperature sensor ....................................... 50-255
Removal and installation of KOMTRAX terminal assembly .................................................. 50-256
60 Maintenance standard................................................................................................................... 60-1
Engine mount ...................................................................................................................... 60-3
Cooling system .................................................................................................................... 60-4
Power train system ..................................................................................................................... 60-5
Swing circle ......................................................................................................................... 60-5
PC360LC-10 00-11
Index
Swing machinery ................................................................................................................. 60-6

Final drive ........................................................................................................................... 60-8
Sprocket............................................................................................................................ 60-10
Idler .................................................................................................................................. 60-14
Track roller ........................................................................................................................ 60-16
Carrier roller ...................................................................................................................... 60-18
Track shoe ........................................................................................................................ 60-19
Hydraulic tank.................................................................................................................... 60-22
Main pump ........................................................................................................................ 60-23
Control valve ..................................................................................................................... 60-24
Swing motor ...................................................................................................................... 60-34
Travel motor ...................................................................................................................... 60-36
PPC valve ......................................................................................................................... 60-39
Solenoid valve ................................................................................................................... 60-50
Attachment circuit selector valve ......................................................................................... 60-51
Center swivel joint .............................................................................................................. 60-52
Work equipment ....................................................................................................................... 60-53
Work equipment................................................................................................................. 60-53
Work equipment cylinder .................................................................................................... 60-62
80 Appendix...................................................................................................................................... 80-1
Air conditioner components ......................................................................................................... 80-3
Precautions for refrigerant..................................................................................................... 80-3
Air conditioner component .................................................................................................... 80-4
Configuration and function of refrigeration cycle...................................................................... 80-7
Outline of refrigeration cycle.................................................................................................. 80-8
Air conditioner unit ............................................................................................................. 80-10
Dual pressure switch .......................................................................................................... 80-17
Air conditioner controller ..................................................................................................... 80-18
Compressor....................................................................................................................... 80-19
Condenser ........................................................................................................................ 80-20
Receiver drier .................................................................................................................... 80-21
Sunlight sensor .................................................................................................................. 80-22
Outer temperature sensor (outside air temperature sensor) ................................................... 80-23
Procedure for testing and troubleshooting ............................................................................ 80-24
Circuit diagram and arrangement of connector pins............................................................... 80-26
System diagram................................................................................................................. 80-28
Input and output signals of the air conditioner controller ......................................................... 80-29
Parts and connectors layout................................................................................................ 80-31
Layout of air conditioner related parts and connectors ........................................................... 80-32
Testing air leakage (duct) .................................................................................................... 80-35
Testing with self-diagnosis function ...................................................................................... 80-38
How to open the electrical system abnormality record screen in service mode of the machine
monitor ................................................................................................................ 80-39
Testing vent (mode) changeover.......................................................................................... 80-41
Testing FRESH/RECIRC air changeover.............................................................................. 80-43
Testing sunlight sensor ....................................................................................................... 80-44
Testing (dual) pressure switch for refrigerant......................................................................... 80-45
Testing relays .................................................................................................................... 80-47
Troubleshooting chart 1 ...................................................................................................... 80-48
Failure code list related to air conditioner.............................................................................. 80-53
Failure code [879AKA] A/C Inner sensor Open Circuit ........................................................... 80-54
Failure code [879AKB] A/C Inner sensor Short Circuit ........................................................... 80-55
Failure code [879BKA] A/C Outer sensor Open Circuit .......................................................... 80-56
00-12 PC360LC-10
Index
Failure code [879BKB] A/C Outer sensor Short Circuit .......................................................... 80-58
Failure code [879CKA] Ventilating sensor Open Circuit ......................................................... 80-60
Failure code [879CKB] Ventilating sensor Short Circuit.......................................................... 80-61
Failure code [879DKZ] Sunlight sensor Open or Short Circuit ................................................ 80-62
Failure code [879EMC] Ventilating Damper Abnormality ........................................................ 80-64
Failure code [879FMC] Air Mix Damper Abnormality ............................................................. 80-65
Failure code [879GKX] Refrigerant Abnormality .................................................................... 80-66
A-1 Troubleshooting for power supply system (Air conditioner does not operate) ..................... 80-67
A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled) ........................ 80-69
A-3 Troubleshooting for blower motor system (No air comes out or air flow is
abnormal) ............................................................................................................ 80-72
A-4 Troubleshooting for FRESH/RECIRC air changeover ...................................................... 80-74
Troubleshooting with gauge pressure................................................................................... 80-76
Connection of service tool................................................................................................... 80-79
Precautions for disconnecting and connecting air conditioner piping ....................................... 80-81
Handling of compressor oil.................................................................................................. 80-83
90 Diagrams and drawings................................................................................................................. 90-1
Hydraulic circuit diagram ............................................................................................................. 90-3
Symbols in hydraulic circuit diagram ...................................................................................... 90-3
Hydraulic circuit diagram....................................................................................................... 90-7
Electric circuit diagram ................................................................................................................ 90-9
Symbols in electric circuit diagram ......................................................................................... 90-9
Electric circuit diagram........................................................................................................ 90-13
Electric circuit diagram for air conditioner unit ....................................................................... 90-25
Failure code [CA3741] Rail Press Valve Trip Error ................................................................................
Index.................................................................................................................................................................... 1
PC360LC-10 00-13
Foreword, safety and general information
Foreword, safety and general information (ALL-0370-001-A-00-A)
Important safety notice (ALL-1120-012-A-01-A)
(Rev. 2012/10)
• Appropriate servicing and repair are extremely important to ensure safe operation of the machine. The
shop manual describes the effective and safe servicing and repair methods recommended by Komatsu.
Some of these methods require the use of the special tools designed by Komatsu for the specific purpose.
• The symbol mark k is used for such matters that require special cautions during the work. The work
indicated by the caution mark should be performed according to the instructions with special attention to
the cautions. Should hazardous situation occur or be anticipated during such work, be sure to keep safe
first and take every necessary measure.
General precautions knowledge of welding perform the work. When

performing welding work, always wear welding
k Inappropriate handling causes an extreme gloves, apron, shielding goggles, cap, etc.
danger. Read and understand what is • Before starting work, warm up your body
described in the operation and maintenance thoroughly to start work under good condition.
manual before operating the machine. Read • Avoid continuing work for long hours and take
and understand what is described in this rests with proper intervals to keep your body in
manual before starting the work. good condition. Take a rest in a specified safe
place.
• Before performing any greasing or repairs, read
all the safety labels stuck to the machine. For Safety points
the locations of the safety labels and detailed 1 Good arrangement
explanation of precautions, see the operation 2 Correct work clothes
and maintenance manual.
3 Observance of work standard
• Locate a place in the repair workshop to keep
4 Practice of making and checking signals
the tools and removed parts. Always keep the
Prohibition of operation and handling by
tools and parts in their correct places. Always 5
unlicensed workers
keep the work area clean and make sure that Safety check before starting work
6
there is no dirt, water or oil on the floor. Smoke
Wearing protective goggles (for cleaning or
only in the areas provided for smoking. Never 7 grinding work)
smoke while working.
Wearing shielding goggles and protectors (for
• When performing any work, always wear the 8 welding work)
safety shoes and helmet. Do not wear loose
9 Good physical condition and preparation
work cloths, or clothes with buttons missing.
Precautions against work which you are not
1. Always wear the protective eyeglasses when 10 used to or you are used to too much
hitting parts with a hammer.
2. Always wear the protective eyeglasses when Preparation
grinding parts with a grinder, etc. • Before adding oil or making any repairs, place
• When performing any work with two or more the machine on a firm and level ground, and
workers, always agree on the working procedure apply the parking brake and chock the wheels or
before starting. While working, always keep tracks to prevent the machine from moving.
conversations of the work between your fellow • Before starting work, lower the work equipment
workers and your self on any step of the work. (blade, ripper, bucket, etc.) to the ground. If it is
During the work, hang the warning tag of not possible to lower the equipment to the
"UNDER WORKING" in the operator's ground, insert the lock pin or use blocks to
compartment. prevent the work equipment from falling. And be
• Only qualified workers must perform the work sure to lock all the work equipment control levers
and operation which require license or and hang a warning tag on them.
qualification. • When performing the disassembling or
• Keep the tools in good condition. And learn the assembling work, support the machine securely
correct way to use the tools, and use the proper with blocks, jacks, or stands before starting the
ones among them. Before starting the work, work.
thoroughly check the tools, lift truck, service • Remove all of mud and oil from the steps or
vehicle, etc. other places used to get on and off the machine
• If welding repairs is required, always have a completely. Always use the handrails, ladders of
trained and experienced welder with good
00-14 PC360LC-10
steps when getting on or off the machine. Never • When removing piping, prevent the fuel or oil
jump on or off the machine. When the scaffold is from spilling out. If any fuel or oil drips onto the
not provided, use steps or stepladder to secure floor, wipe it off immediately. Fuel or oil on the
your footing. floor can cause you to slip and can even cause
fires.
Precautions during work • As a general rule, do not use gasoline to wash
• For the machine equipped with the battery parts. Do not use gasoline to clean the electrical
disconnect switch, check that the system parts, in particular.
operating lamp is turned off before starting the • Reinstall the parts removed to their original
work. Then, turn the battery disconnect switch to places. Replace the damaged parts and the
OFF (Q) position and remove the switch key. For parts which must not be used with new ones.
the machine not equipped with the battery When installing the hoses and wiring harnesses,
disconnect switch, remove the cable from the be careful that they are not damaged by
battery before starting the work. Be sure to contacting with other parts when the machine is
remove the negative end (-) of the battery cable operated.
first. • When connecting the high pressure hoses and
• Release the remaining pressure in the circuits tubes, make sure that they are not twisted. The
completely before the work when the parts in the damaged high pressure hoses and tubes are
circuits of oil, fuel, coolant and air are very dangerous when they are installed. So, be
disconnected or removed. When the cap of the extremely careful when connecting the high
oil filter, drain plug or oil pressure pickup plug is pressure pipings. In addition, check that their
removed, loose them slowly to prevent the oil connections are correct.
from spurting out. • When assembling or installing the parts, be sure
• When removing or installing the checking plug or to tighten the bolts to the specified torque. When
the piping in the fuel circuit, wait 30 seconds or installing the protective parts such as guards, or
longer after the engine is shut down and start the parts which vibrate violently or rotate at high
the work after the remaining pressure is speeds, be sure to check that they are installed
released from the fuel circuit. correctly.
• Immediately after the engine is shut down, the • When aligning 2 holes, never insert your fingers
coolant and oil in the circuits are hot. Be careful or hand into the holes. Align the holes with care
not to get scalded by the hot coolant and oil. so that your fingers are not caught in the hole.
Start the work after checking that the coolant • When measuring hydraulic pressure, check that
and oil are cooled down sufficiently. the measuring tools are correctly installed.
• Start the work after the engine is shut down. Be • Pay attention to safety when removing and
sure to shut down the engine when working on installing the tracks of the track type machines.
or around the rotating parts in particular. When When removing the track, it separates suddenly.
checking the machine without shutting down the The workers should not stand at either end of
engine (measuring oil pressure, rotational speed, the track.
oil or coolant temperature), take extreme care • If the engine is operated for a long time in a
not to get caught in the rotating parts or the closed place which is not ventilated well, you
working equipment. may suffer from gas poisoning. Accordingly,
• The hoist or crane must be used to sling the open the windows and doors to ventilate the
components weighing 25 kg or heavier. Check place well.
the slings (wire rope, nylon sling, chain and
hook) for damage before the work. Use the Precautions for slinging work and making
slings with ample capacity and install them to signals
the proper places. Operate the hoist or crane • Only one appointed worker must make signals
slowly to prevent the component from hitting any and co-worker must communicate with each
other part. Do not work with any part still raised other frequently. The appointed signaler must
by the hoist or crane. make specified signals clearly at the place
• When removing the part which is under internal where the signaler is well seen from the
pressure or reaction force of the spring, always operator's seat and where the signaler can see
leave 2 bolts in diagonal positions. Loosen those the working condition easily. The signaler must
2 bolts gradually and alternately and release the always stand in front of the load and guide the
pressure, then, remove the part. operator safely.
• When removing the part, be careful not to break 1. Do not stand under the load.
or damage the electrical wiring. The damaged 2. Do not step on the load.
wiring may cause electrical fires. • Check the slings before starting sling work.
PC360LC-10 00-15
• Keep putting on the gloves during sling work. • Use the specified eye bolts and fix wire ropes,
(Put on the leather gloves, if available.) chains, etc. to them with shackles, etc.
• Measure the weight of the load by the eye and • Apply wire ropes to the middle part of the hook.
check its center of gravity.
a Slinging near the tip of the hook may cause
• Use the proper sling according to the weight of
the rope to slip off the hook during hoisting.
the load and method of slinging. If too thick wire
The strength of the hook is maximum at its
ropes are used to sling a light load, the load may
central part.
slip and fall.
• Do not sling a load with 1 wire rope only. If do so,
the load may rotate or the sling gets loose and
the sling may slip off. Install 2 or more wire ropes
symmetrically.
k Slinging with one rope may cause turning

of the load during hoisting, untwisting of
the rope, or slipping of the rope from its
original slinging position on the load,
which can result in a dangerous accident.
• Hanging angle must be 60 degrees or smaller as
a rule.
• When hanging a heavy load (25kg or heavier), • Do not use twisted or kinked wire ropes.
the hanging angle of the rope must be narrower • When slinging up a load, observe the following.
than that of the hook.
1. Wind up the rope slowly until the wire rope
a When slinging a load with 2 ropes or more, tensions. When putting your hands on the
the larger the hanging angle is, the larger the wire ropes, do not grasp them but press them
tension of each rope. The figure bellow down from above. If you grasp them, your
shows the variation of allowable load in kN fingers may be caught.
{kg} when hoisting is made with 2 ropes, 2. After the wire ropes are stretched, stop the
each of which is allowed to sling up to 9.8 kN crane and check the condition of the slung
{1000kg} a load vertically, at various hanging load, wire ropes, and pads.
angles. When the 2 ropes sling a load 3. If the load is unstable or the wire rope or
vertically, up to19.6 kN {2000 kg} of total chains are twisted, lower the load and lift it
weight can be suspended. This weight is up again.
reduced to 9.8 kN {1000 kg} when the 2 4. Do not lift up the load at an angle.
ropes make a hanging angle of 120 degrees. • When lowering a load, pay attention to the
If the two ropes sling a 19.6 kN {2000 kg} following.
load at a hanging angle of 150 degrees, each 1. When lifting down a load, stop it temporarily
rope is subjected to a force as large as 39.2 at 30 cm above the floor, and then lower it
kN {4000 kg}. slowly.
2. Check that the load is stable, and then
remove the sling.
3. Remove kinks and dirt from the wire ropes
and chains used for the sling work, and put
them in the specified place.
Precautions for using mobile crane

a Read the Operation and Maintenance Manual of
the crane carefully in advance and operate the
crane safely.
Precautions for using overhead traveling crane

k The hoist or crane must be used to sling the
• When installing wire ropes to an angular load,
components weighing 25 kg or heavier. A
apply pads to protect the wire ropes. If the load
part weighing 25 kg or heavier in
is slippery, apply proper material to prevent the
"disassembly and assembly" section is
wire rope from slipping.
indicated with the symbol of 4 .
00-16 PC360LC-10
• Before starting work, check the wire ropes, Nominal

diameter of rope Allowable load
brake, clutch, controller, rails, over winding
prevention device, ground fault circuit interrupter mm kN ton
for electric shock prevention, crane collision 50 221.6 22.6
prevention device, and energizing warning lamp, 60 318.3 32.4
and check the following safety items.
• Observe the signals for sling work. a The allowable load is calculated as one sixth of
• Operate the hoist at a safe place. the breaking load of the rope to be used (safety
• Be sure to check the directions of the direction coefficient: 6).
indication plate (north, south, east and west) and
the operating button. Precautions for disconnecting and connecting
hoses and tubes in air conditioner circuit
• Do not sling a load at an angle. Do not move the
crane while the slung load is swinging. Disconnection
• Do not raise or lower a load while the crane is
k When replacing the air conditioner unit, air
moving longitudinally or laterally.
• Do not drag a sling. conditioner compressor, condenser or
• When lifting up a load, stop it just after it leaves receiver drier, etc., collect the refrigerant (air
the ground and check safety, and then lift it up. conditioner gas: R134a) from the air
• Consider the travel route in advance and lift up a conditioner circuit before disconnecting the
load to a safe height. air conditioner hoses.
• Place the control switch in a position where it will
a Ask a qualified person for collecting, adding and
not be an obstacle to work and passage.
filling operations of the refrigerant (air
• After operating the hoist, do not swing the
conditioner gas: R134a). (Only registered
control switch.
persons can work.)
• Remember the position of the main switch so
that you can turn off the power immediately in an a Never release the refrigerant (air conditioner
emergency. gas: R134a) to the atmosphere.
• Shut down the main switch when the hoist stops
k If refrigerant gas (air conditioner gas: R134a)
because of a blackout. When turning on a switch
which is turned OFF by the ground fault circuit gets in your eyes, you may lose your sight.
interrupter for electric shock prevention, check And if it touches your skin, you may suffer
that the devices related to that switch are not in from frostbite. Put on protective eyeglasses,
operating condition. gloves and working clothes with long
• If you find an obstacle around the hoist, stop the sleeves while collecting the refrigerant or
operation. filling the air conditioner circuit with the
• After finishing the work, stop the hoist at the refrigerant.
specified position and raise the hook to at least 2
• When loosening the nuts fixing air conditioner
meters above the floor. Do not leave the sling
hoses and tubes, be sure to use 2 wrenches;
attached to the hook.
use one wrench to fix and use the other one to
Selecting wire ropes loosen the nut.
• Select adequate ropes depending on the weight
Connection
of the parts to be hoisted, referring to the table
• When installing the hose for the air conditioner
below
circuit, take care not to allow invasion of dirt,
Wire rope (JIS G3525, 6 x 37 - Type A)
dusts and water into the hose.
(Standard Z twist wire ropes without galvanizing) • Check that the O-rings are fitted to the joints
Nominal when connecting the air conditioner piping.
diameter of rope Allowable load • Once an O-ring is used, it is deformed and
mm kN ton deteriorated. Accordingly, do not reuse it.
10 8.8 0.9 • When removing the O-rings, use a soft tool so
that the piping is not damaged.
12 12.7 1.3
• Check that the O-ring is not damaged or
14 17.3 1.7
deteriorated.
16 22.6 2.3 • Apply compressor oil for refrigerant (R134a) to
18 28.6 2.9 the O-ring.
20 35.3 3.6
25 55.3 5.6 a However, do not apply oil to the threaded
portion of a bolt, nut or union.
30 79.6 8.1
40 141.6 14.4
PC360LC-10 00-17
Manufacturer Part name

DENSO ND-OIL8
VALEO THERMAL ZXL100PG (equivalent to
SYSTEMS PAG46)
SANDEN SP-10
• When tightening nuts of the air conditioner
hoses and tubes, be sure to use 2 wrenches.
Use one wrench to fix and tighten the nut with
the other wrench to the specified torque (Use a
torque wrench for tightening).
a Example of fitting of O-ring
• An O-ring is fitted to every joint of the air
conditioner piping.
For tightening torques, see "Others",

"Precautions for disconnection and connection
of air conditioner piping".
00-18 PC360LC-10
Fire prevention (ALL-0000-001-K-27-A)
Action if fire occurs (ALL-0000-17A-K-01-A)

• Turn the starting switch to OFF position to stop
the engine.
• Use the handrails and steps to get off the
machine.
• Do not jump off the machine. You may fall or
suffer serious injury.
• The fume generated by a fire contains harmful 9 J D 0 1 7 2 0
materials which have a bad influence on a
human body when they are sucked.
Don't breathe a fume.
• After a fire, there may be harmful compounds
left. If it touches your skin it may have a bad
influence on your body.
Be sure to wear rubber gloves when handle the
materials left after the fire.
The material of the gloves, which is
recommended is polychloroprene (Neoprene) or
polyvinyl chloride (in the lower temperature 9 J D 0 1 7 2 1
environment).
When wearing cotton-work-gloves, wear rubber • Fire caused by accumulation or attachment
gloves under them. of flammable material
• Remove any dry leaves, chips, pieces of
Prevent fire (ALL-0000-17B-K-03-A) paper, coal dust, or any other flammable
• Fire caused by fuel, oil, coolant or window materials accumulated or attached to or
washer fluid around the engine exhaust manifold, muffler,
Do not bring any flame or fire close to flammable or battery, or on the undercovers.
substances such as fuel, oil, coolant or window • To prevent fires from being caught, remove
washer fluid.There is danger that they may catch any flammable materials such as dry leaves,
fire. Always observe the following. chips, pieces of paper, coal dust, or any
• Do not smoke or use any flame near fuel or other flammable materials accumulated
other flammable substances. around the cooling system (radiator, oil
• Shut down the engine before adding fuel. cooler) or on the undercover.
• Do not leave the machine when adding fuel • Fire coming from electric wiring
or oil. Short circuits in the electrical system can cause
• Tighten all the fuel and oil caps securely. fire. Always observe the following.
• Be careful not to spill fuel on overheated • Keep all the electric wiring connections clean
surfaces or on parts of the electrical system. and securely tightened.
• After adding fuel or oil, wipe up any spilled • Check the wiring every day for looseness or
fuel or oil. damage. Reconnect any loose connectors or
• Put greasy rags and other flammable refasten wiring clamps. Repair or replace any
materials into a safe container to maintain damaged wiring.
safety at the workplace. • Fire caused by piping
• When washing parts with oil, use a non- Check that all the clamps for the hoses and
flammable oil. Do not use diesel oil or tubes, guards, and cushions are securely fixed
gasoline.There is danger that they may catch in position.
fire. If they are loose, they may vibrate during
• Do not weld or use a cutting torch to cut any operation and rub against other parts. There is
pipes or tubes that contain flammable liquids. danger that this may lead to damage to the
• Determine well-ventilated areas for storing oil hoses and cause high-pressure oil to spurt out,
and fuel. Keep the oil and fuel in the leading to fire and serious personal injury or
specified place and do not allow death.
unauthorized persons to enter. • Fire around the machine due to highly heated
• When performing grinding or welding work exhaust gas
on the machine, move any flammable This machine is equipped with KDPF (Komatsu
materials to a safe place before starting. Diesel Particulate Filter).
PC360LC-10 00-19
KDPF is a system for purifying soot in exhaust

gas. Its exhaust gas discharged during
purification process (regeneration) can be at
higher temperature than that from existing
models. Do not bring any flammable material
close to the outlet of the exhaust pipe.
• When there are thatched houses, dry leaves
or pieces of paper near the work site, set the
system to disable the regeneration before
starting work to prevent fire hazards due to
highly heated exhaust gas.
See the operation and maintenance manual
for the setting procedure.
• Explosion caused by lighting equipment
• When checking fuel, oil, battery electrolyte,
or coolant, always use lighting equipment
with anti-explosion specifications.
• When taking the electrical power for the
lighting equipment from the machine itself,
follow the instructions in the operation and
maintenance manual.
Dispose of waste materials (ALL-0000-99A-K-
02-A)
To prevent pollution, pay full attention to the way to

dispose of waste materials.
• Always put the oil and coolant drained from the
machine in containers. Never drain the oil and
coolant directly onto the ground or dump into the
sewage system, rivers, the sea, or lakes.
• Observe the related laws and regulations when
disposing of harmful objects such as oil, fuel,
coolant, solvent, filters, and batteries.
Some kinds of rubber and plastics may produce

poisonous gas harmful to human body when they
are burned.
• As for rubber, plastics, or parts (hoses, cables,
and wiring harnesses, etc.) which contain those
materials, ask the industrial waste treatment
firms for their disposals in accordance with the
local regulations.
00-20 PC360LC-10
How to read the shop manual (ALL-0320-010-A-01-A)
(Rev. 2012/10)
• Some attachments and optional parts described in this shop manual may not be arranged for certain
areas. Contact your Komatsu distributor if one or some of them are required.
• Materials and specifications are subject to change without notice.
• The shop manuals are available for "Machine part" and "Engine part". For the engine, see the shop
manual for the same model of the engine as the one which is mounted on the machine.
Composition of shop manual

• This shop manual describes the technical information required for the services performed in a workshop.
The shop manual is divided into the following chapters for the convenience of use.
00. Index and foreword
• This section includes the index, foreword, safety and basic information.
01. Specification
• This section explains the specifications of the machine.
10. Structure and function
• This section explains the structure and function of the machine. The section of "Structure and function"
serves not only to give an understanding for the structure of each component, but also serves as
reference material for troubleshooting.
20. Standard value table
• The standard values for a new machine and trouble shooting are indicated. This standard value table is
used for testing and adjusting, and determining a failure at troubleshooting.
30. Testing and adjusting
• This section describes the measuring tools and how to measure, and how to adjust various parts. As for
the standard value and failure criterion, see the standard value table.
40. Troubleshooting
• This section describes the troubleshooting in a suspected area when a failure occurs and the remedy for
the failure. Troubleshooting is described by each failure mode.
50. Disassembly and assembly
• This section explains the procedures for removing, installing, disassembling, and assembling each part or
component and the special tools for the works as well as precautions for doing them safely. In addition,
tightening torque, and quantity and weight of coating material, oil, grease, and coolant required for the
works are also explained.
60. Maintenance standard
• This section describes the maintenance standard values for each component. This section gives the
criterion values for each component and required remedy at disassembly or maintenance.
80. Appendix
• The structure and function, testing and adjusting, and troubleshooting for all of the other components or
equipment which can not be separately classified are explained together in the appendix.
90. Diagrams and drawings
• This section gives hydraulic circuit diagrams and electrical circuit diagrams.
PC360LC-10 00-21
Symbol
Important safety and quality portions are marked with the following symbols so that the shop manual is used
practically.
Symbol Item Remarks
Safety The special safety precautions required for performing work are
k described.
The special technical precautions or other precautions for preserving
a Caution standards required when performing work are described.
The weight of part or component and the cautions required when
4 Weight selecting hoisting wire or when working posture is important are
indicated.
Tightening The tightening torques that require special attention during assembly
3 torque work are indicated.
The places to be coated with adhesives, grease, etc. during assembling
2 Coat
are indicated.
Oil, coolant The places where oil, coolant, etc. must be added and the quantity to be
5 added are indicated.
Places where oil, coolant, etc. must be drained and the quantity to be
6 Drain
drained are indicated.
Unit
• In this shop manual, the units are indicated with International System of units (SI).
• For reference, Gravitational System of units which is used to be used is indicated in parentheses of { }.
00-22 PC360LC-10
Explanation of terms for maintenance standard (ALL-0330-006-A-01-A)
(Rev. 2012/10)
• The chapter of maintenance standard shows judgement criteria to determine the products to be replaced
or to be reused. The judgement criteria are described by using the following terms.
Standard dimension and tolerance • When some parts are repaired, the value of
• To be accurate, the finished dimension of a part performance/function is set to the standard
is slightly different from one to another. value.
• The finished dimension of a part specifies the
allowable difference from the standard
dimension which is set first.
• The dimension set as the standard is called the
standard dimension and the range of difference
from this standard dimension is called the
"tolerance".
• An indication example of a standard dimension
and tolerance is shown in the following table.
(The standard dimension is entered on the left
side and the tolerance is entered with a positive
or negative symbol on the right side)
Example:
Standard dimension Tolerance
-0.022
120
-0.126
• The tolerance may be indicated in the text and a
table as "standard dimension (upper limit of
tolerance/lower limit of tolerance)."
Example: 120(-0.022/-0.126)
• Usually, the dimension of a hole and the
dimension of a shaft to be inserted into the hole
are indicated by the same standard dimension
and different tolerances of the hole and shaft.
The tightness of fit is decided by the tolerance.
• An indication example of a shaft and hole is
shown in the following table.
Standard interference
(The standard dimension is entered on the left
• When the diameter of a hole of a part shown in
side and the tolerance of the shaft is entered
with a positive or negative symbol at the center the given standard dimension and tolerance
table is smaller than that of the shaft to be
and that of the hole on the right side)
inserted, the difference between those
Standard Tolerance diameters is called the "interference".
dimension Shaft Hole • Subtract the maximum dimension of the hole
-0.030 +0.046 from the minimum dimension of the shaft and
60
-0.076 0 call it (A). Subtract the minimum dimension of
the hole from the maximum dimension of the
Standard clearance and standard value shaft and call it (B). The range between (A) and
• The clearance made when new parts are (B) is the "standard interference".
assembled is called the standard clearance, • After repairing or replacing some parts, measure
which is indicated by the range from the the dimension of their hole and shaft and check
minimum clearance to the maximum clearance. that the interference is in the standard range.
• When some parts are repaired, the clearance is
generally adjusted to the standard clearance. Repair limit and allowable value or allowable
• The values indicating performance and function dimension
of new products or equivalent are called the • The dimensions of parts change because of the
"standard value", which is indicated by a range wear or deformation while they are used. When
or a target value. the dimension changes exceeding certain value,
PC360LC-10 00-23
the parts can not be used any longer. This value

is called "repair limit".
• If a part is worn to the repair limit, it must be
replaced or repaired.
• The performance and function of the products
lower while they are used. When the value of the
performance and function lowers exceeding a
certain limit and it influences the operation etc.,
this value is called the allowable value or
allowable dimension.
• A product whose dimension is out of the
allowable value, must be repaired. However,
since the allowable values are generally
estimated through various tests or experiences
in most cases, the judgement must be made in
consideration of the operating condition and
customer's requirement.
Allowable clearance
• Parts can be used until the clearance between
them is increased to a certain limit. The limit at
which those parts cannot be used is called the
"allowable clearance".
• If the clearance between the parts exceeds the
allowable clearance, they must be replaced or
repaired.
Allowable interference
• The allowable maximum interference between
the hole of a part and the shaft of another part to
be assembled is called the "allowable
interference".
• The allowable interference shows the repair limit
of the part of smaller tolerance.
• The parts whose interferences are out of the
allowable interference must be replaced or
repaired.
00-24 PC360LC-10
Handling equipment of fuel system devices (PC-AD00-2A4-K-00-A)
(Rev. 2012/01)
• The common rail fuel injection system (CRI)
consists of more precise parts than the parts
used in the conventional fuel injection pump and
nozzle. If foreign material enters this system, it
may cause a failure. Use special care to prevent
entry of the foreign material when servicing the
fuel system.
Use care for working environment

• Avoid filter change or repairing the machine in
rain or high winds, or at places where there is a
lot of dust.
Sealing openings
• Plug the pipes and the openings of the
components which are removed with the caps,
tapes, vinyl bags, etc. to prevent foreign material
from entering. Never perform repair works under
the condition that the openings are left as they
are or plugged with cloths as foreign material
may enter or environment may be polluted by
the oil leaked. Do not discard the waste oil
somewhere or other. Hand it over to your
customer for disposal, or dispose it by yourself.
How to clean parts when dirt is stuck

• If any dirt or dust sticks the parts of the fuel
system, clean it off thoroughly with clean fuel.
Precautions for replacing fuel filter cartridge

• Be sure to use the Komatsu genuine fuel filter
cartridge.
• The common rail fuel injection system (CRI)
consists of more precise parts than the parts
used in the conventional fuel injection pump and
nozzle. In order to prevent foreign material from
entering this system, the filter employs a
specially high performance of filter element. If a
filter element other than the genuine one is used,
the fuel system may have a failure. Accordingly,
never use such a filter element.
PC360LC-10 00-25
Handling of intake system parts (PC220-A900-2A4-K-00-A)
(Rev.2012/01)
• The Komatsu Variable Geometry Turbocharger
(KVGT) consists of more precise parts (variable
mechanism) than the parts used in the
conventional turbocharger. If foreign material
enters this system, it may cause a failure. Use
special care to prevent entry of the foreign
material when servicing the air intake system.
Be careful of working environment

• Avoid the repair work of the machine in rain or
strong wind or at the places where there is a lot
of dust.
Sealing openings
components which are removed, with the caps,
tapes, vinyl bags, etc. to prevent foreign material
from entering. Never perform repair works under
the condition that the openings are left open or
plugged with rag since foreign material may
enter.
00-26 PC360LC-10
Handling of hydraulic equipment (ALL-C000-2A4-P-01-A)
(Rev. 2012/10)
• With the increase in pressure and precision of the hydraulic components, the most common cause of a
failure is dirt (foreign material) in the hydraulic circuit. Therefore, the special care must be taken when
adding hydraulic oil,or when disassembling or assembling the hydraulic components.
Be careful of working environment

• Avoid adding hydraulic oil, replacing filters, or
repairing the machine in rain or high winds, or at
places where there is a lot of dust.
Disassembly and maintenance work in the field

• When disassembly or maintenance work of the
hydraulic is performed in the field, there is
danger of dust entering the components. It is
also difficult to check the performance of the
components after repairs, so it is desirable to
use the component exchange service. The
disassembly and assembly of the hydraulic
components must be performed in the specially
arranged dustproof workshop and the Preventing intrusion of foreign materials during
performance test of the components must be refilling operations.
performed with the special testing equipment. • Care must be taken when adding hydraulic oil so
that foreign material does not enter. Keep the oil
filler port and the area around it, oil supply pump
and oil container clean. If an oil cleaning device
is used, it is possible to remove the dirt that is
collected during storage. It is a surer means.
Plugging of opening (prevention of flowing out

of oil)
components which are removed (when plugs
are not prepared, seal with caps, tapes, vinyl
bags, etc.) to prevent entry of foreign material Replacing hydraulic oil while its temperature is
and flowing out of oil. Never leave the openings high
• When the hydraulic oil is warm, it flows easily. In
of the pipes and hoses without being covered or
addition, sludge can also be drained from the
plugged with cloth as foreign material may enter
them or environment may be polluted by the oil circuit together with the oil. So, it is better to
leaked. Do not discard the waste oil somewhere change the hydraulic oil while it is warm. When
or other. Hand it over to your customer for changing the hydraulic oil, the old oil must be
disposal, or dispose it by yourself. drained as much as possible. (Drain the oil not
only from the hydraulic tank, but also from the
filter housing and the drain plug hole in the
circuit.) If the old oil is left in the system, the
contaminant and sludge in the oil mix with the
new oil and shorten the life of the new hydraulic
oil.
PC360LC-10 00-27
Flushing operations
• After disassembling the equipment or when
changing the hydraulic oil with new one, flush
the system to remove the contaminant and
sludge left in the hydraulic circuit as well as the
oil which includes them. Normally, flushing is
performed twice. Primary flushing is performed
by use of the flushing oil and the secondary
flushing is performed by use of the specified
hydraulic oil.
Cleaning operations
• After repairing the hydraulic equipment (pump,
control valve, etc.) or when the machine is in
operation, perform oil cleaning to remove the
sludge or contaminant in the hydraulic oil circuit.
The oil cleaning equipment can remove the ultra
fine (approximately 3 μm) particles that the filter
built in the hydraulic equipment can not remove.
So, it is an extremely effective device.
00-28 PC360LC-10
Method of disconnecting and connecting of push-pull type coupler (ALL-

C930-001-P-00-A)
(Rev. 2012/01)
k Loosen the oil filler cap of the hydraulic tank slowly to release the remaining pressure in the
hydraulic tank.
k Even if the remaining pressure is released from the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly, prepare an oil container.
Type 1 (ALL-C930-925-P-01-A)
Disconnection Connection
1. Hold adapter (1) and push hose joint (2) into 1. Hold hose adapter (1) or hose (5) and insert it in
mating adapter (3). (Fig. 1) mating adapter (3) aligning them with each other.
(Fig. 4)
a It can be pushed in by approximately 3.5mm.
a Do not hold rubber cap part (4).
a Do not hold rubber cap portion (4).
2. After inserting the hose fitting in the adapter on
2. While pushing hose joint (2) into adapter (3),
the other side perfectly, pull it back to check the
push rubber cap (4) against adapter (3) until
connecting condition. (Fig. 4)
"click" is heard. (Fig. 2)
3. Hold hose adapter (1) or hose (5) and pull it out. a When the hose fitting is pulled back, the
(Fig. 3) rubber cap will move toward the hose,
however, it is not a problem.
a Since some hydraulic oil flows out, prepare
an oil container.
PC360LC-10 00-29
Type 2 (ALL-C930-925-P-02-A)
1. While holding the fitting, push body (7) in straight 1. While holding the fitting, push body (7) in straight
until sliding prevention ring (6) hits contact until sliding prevention ring (6) hits contact
surface (a) at the hexagonal part on the male surface (a) at the hexagonal part on the male
side. (Fig. 6) side to connect it. (Fig. 9)
2. While keeping the condition of Step 1, turn lever
(8) to the right (clockwise). (Fig. 7)
3. While keeping the conditions of Steps 1 and 2,
pull out whole body (7) to disconnect it. (Fig. 8)
00-30 PC360LC-10
Type 3 (ALL-C930-925-P-03-A)
1. While holding the fitting, push body (9) in straight 1. While holding the fitting, push body (9) in straight
until sliding prevention ring (8) hits contact until sliding prevention ring (8) hits contact
surface (b) at the hexagonal portion on the male surface (a) at the hexagonal portion on the male
side. (Fig. 10) side to connect them. (Fig. 13)
2. While keeping the condition of Step 1, push
cover (10) straight until it hits contact surface (b)
of the hexagonal portion on the male side. (Fig.
11)
3. While keeping the conditions of Steps 1 and 2,
pull out whole body (9) to disconnect it. (Fig. 12)
PC360LC-10 00-31
Handling of electrical equipment (ALL-E000-2A4-P-01-A)
(Rev. 2012/11)
• To maintain the performance of the machine over a long period, and to prevent failures or troubles before
they occur, correct "operation", "maintenance and inspection" "troubleshooting", and "repairs" must be
performed. This section deals particularly with correct repair procedures for mechatronics components
and is aimed at improving the quality of repairs. For this purpose, it describes the working procedures in
"Handling of electrical equipment".
Precautions for handling electric equipment
Handling wiring harnesses and connectors

• Wiring harnesses consist of wires connecting
one component to another component,
connectors used for connecting and
disconnecting one wire from another wire, and
protectors or tubes used for protecting the wires.
• Compared with other electrical components
fitted in boxes or cases, wiring harnesses are
more likely to be affected by the direct effects of
rain water, heat, or vibration. Furthermore,
during inspection and repair operations, they are
frequently removed and installed again, so they Defective crimping or soldering of connectors
are likely to suffer deformation or damage. For
this reason, it is necessary to be extremely • The pins of the male and female connectors are
careful when handling the wiring harnesses. attached to wires by crimping or soldering. If
excessive force is applied to the wire, the joining
area may become loose, which may result in a
defective connection or breakage.
Main failures occurring in wiring harness

Defective contact of connectors (defective
contact between male and female connectors) Disconnections in wiring
• Problems with defective contact are likely to • If the wiring harness is pulled to disconnect the
occur because the male connector is not connector, or the components are lifted with a
properly inserted into the female connector,or crane while the wiring harness is still connected,
because one or both of connectors are or a heavy object hits the wiring harness, the
deformed or the position is not correctly aligned, crimping of the connector may separate, or the
or because there is corrosion or oxidization of soldering may be damaged, or the wiring
the contact surfaces. The corroded or oxidized harness may be broken.
contact surfaces may become shiny again (and
contact may become normal) by connecting and
disconnecting the connectors approximately 10
times.
00-32 PC360LC-10
blow it with compressed air and spray it with

electrical contact restorer.
a When wiping the joint portion of the
connector, be careful not to apply excessive
force or deform the pins.
a If there is oil or water in the compressed air, it
causes the contacts to become dirtier. So,
remove the oil and water from the
compressed air completely before cleaning
the connector with the compressed air.
High-pressure water entering connector

• The connector is designed to make it difficult for
water to enter (drip-proof structure), but if high-
pressure water is sprayed directly on the
connector, water may enter the connector,
depending on the direction of the water jet.
Accordingly, take care not to spray water over
the connector.
The connector is designed to prevent water from
entering, but once water does enter, it is difficult
to drain it. If water should get into the connector,
the pins will be short-circuited by the water. So if
any water gets in, immediately dry the connector Removing, installing, and drying connectors
and wiring harnesses
or take other appropriate action before passing
Disconnecting connectors
electricity through it.
1. Hold the connectors when disconnecting.
• Disconnect connectors by holding the
connector bodies. For the connectors held by
a screw, loosen the screw fully, then hold the
male and female connectors with each hand
respectively and pull them apart horizontally.
For the connectors with lock stopper, press
down the stopper with your thumb and pull
the connectors apart.
a Never pull the connector with one hand.
Entry of water, mud or dirt when disconnecting a

connector
• If any water, mud or dirt is stuck to the outside
surface of a connector, it can enter inside the
connector when the connector is disconnected.
Before disconnecting the connector, wipe off any
stuck water or dirt by using a piece of dry cloth
or blow it with compressed air.
Oil, mud or dirt stuck to connector
• If any oil or grease is stuck to the connector and
an oil film is formed on the mating surface of the 2. When removing from clips
male and female pins, the oil prevents electricity • Both of the connector and clip have stoppers,
from passing through, resulting in defective which are engaged with each other when the
contact. If any oil or grease, mud or dirt is stuck connector is connected.
to the connector, wipe it off with a dry cloth or
PC360LC-10 00-33
• Check that there is no oil, dirt or water stick

to the connector pins (joint portion).
• Check that the connector pins are free from
deformation, defective contact, corrosion, or
damage.
• Check that external surfaces of the
connectors are free from damage or
breakage.
a If any oil, water or dirt is stuck to the
connector, wipe it off with a dry cloth. If any
water is inside the connector, warm the
connector and the inside of the wiring
• When removing a connector from a clip, pull harness with a dryer. But be careful not to
the connector in a parallel direction to the clip make it too hot as it causes short circuit.
for removing stoppers. a If there is any damage or breakage, replace
a If the connector is pried up and down or the connector.
to the right and left, the housing may 2. Fix the connector securely.
break. • Align the connectors correctly, and fit them
securely. For the connectors with the lock
stopper, push in the connectors until "click" is
heard.
3. Action to take after removing connectors

• After removing the connector, cover it with
the vinyl bag to prevent entry of dust, dirt,oil
or water in the contact portion. 3. Correct the protrusion of the boot and
misalignment of the wiring harness
a If the machine is left disassembled for a • For connectors fitted with the boot, correct
long time, it is particularly easy for any extrusion of the boot. In addition, if the
improper contact to occur, so always wiring harness or the clamp is out of the
cover the connector. position, put it in its original position.
a If the connector cannot be corrected
easily, remove the clamp and adjust the
position.
Connecting connectors
1. Check the connector visually.
00-34 PC360LC-10
• If the connector clamp is removed, be sure to Drying wiring harness

return it to its original position. And check • If there is any oil or dirt on the wiring harness,
that it is securely installed. wipe it off with a dry cloth. Avoid washing by
using steam. If the wire harness must be
washed in water, do not apply high pressure
water or steam directly to the wiring harness. If
water gets directly on the connector, do as
follows.
1. Disconnect the connector and wipe off the water
with a dry cloth.
a If the connector is to be blown with dry
compressed air, there is a risk that oil in the
air may cause defective contact of the
conditioner, remove oil and water in the air
before starting air blow.
Handling of Deutsch connector (DT8-pin, DT12-
pin)
Disconnection
1. While pressing locks (a) and (b) from each side
respectively, pull out female connector (2).
2. Dry the inside of the connector with a dryer.

If water gets inside the connector, use a dryer to
dry the connector.
a Hot air from the dryer can be used, but
regulate the time to use hot air in order to
prevent the connector or related parts from
Connection becoming too hot, as it causes deformation
1. Push in female connector (2) horizontally until or damage to the connector.
the lock clicks. (Arrow: x)
2. Since locks (a) and (b) may not be set
completely, push in female connector (2) with
curving movement until the locks are set
normally. (Arrow: x, y, and z)
a Lock (a) in the figure is pulled down (not set
completely), and lock (b) is set completely.
3. Perform a continuity test on the connector.

After drying, leave the wiring harness
disconnected and perform a continuity test to
check for any short circuits between pins caused
by water.
a After the connector is completely dried, blow
the contact restorer and reassemble them.
PC360LC-10 00-35
2. While pressing lock (L2), pull out connector (1).

Handling of connectors used on engine
Slide, lock type

(FRAMATOME-3, FRAMATOME-2)
Disconnection
1. Slide lock (L1) to the right.
2. While pressing lock (L2), pull out connector (1)
toward you.
a In the case that even if lock (L2) is pressed,
connector (1) cannot be pulled out toward
you unless part A floats, float part A with a
small flat-head screwdriver while pressing
lock (L2), and then pull out connector (1)
toward you.
a Lock (L2) is located in the back of connector
(1).
Connection
1. Insert the connector securely until a click is Connection
heard.
1. Insert the connector securely until a click is
(FRAMATOME-24)
heard.
Disconnection
1. Slide down lock (red) (L1). Pull lock type
(PACKARD-2)
Disconnection
1. Disconnect the connector (2) by pulling lock (B)
(on the wiring harness side) of connector (2)
outward.
00-36 PC360LC-10
Connection Connection
1. Insert the connector securely until a click is 1. Insert the connector securely until a click is
heard. heard.
(AMP-3)
Push lock type
(BOSCH-3) Disconnection
Disconnection 1. While pressing lock (E), pull out connector (5) in
the direction of the arrow.
1. While pressing lock (C), pull out connector (3) in
• 114 series
Connection
heard.
• 107 series (SUMITOMO-2)
Disconnection
1. While pressing lock (E), pull out connector (5) in
a If the lock is located on the underside, use

flat-head screwdriver [1] since you cannot
insert your fingers.
While pushing up lock (C) of the connector Connection
with flat-head screwdriver [1], pull out 1. Insert the connector securely until a click is
connector (3) in the direction of the arrow. heard.
PC360LC-10 00-37
(SUMITOMO-3)
Disconnection
1. While pressing lock (E), pull out connector (5) in
a Pull the connector straight up.
Connection
1. Insert the connector to the end while aligning its
grove to the other.
2. Turn housing (H1) in the direction of the arrow
until it "clicks".
Connection
heard.
(SUMITOMO-4)
Disconnection
1. While pressing lock (D), pull out connector (4) in
Handling controller
• The electronic circuits for control including the
microcomputers are assembled in the controller.
These electronic circuits in the controller must
be handled with care as they control the
machine.
• Do not place objects on top of the controller.
Connection
heard.
Turn-housing type (Round green connector)
(CANNON-4)
Disconnection
1. Turn housing (H1) in the direction of the arrow.
a Unlock the connector by turning housing (H1).
When the lock is release the housing is felt
tight to turn.
2. Pull out housing (H1) in the direction of the • Cover the control connectors with tape or a vinyl
arrow. bag. Never touch the connector contacts.
a Housing (H1) is left on the wiring harness • During rainy weather, do not leave the controller
side. in a place where it is exposed to rain.
• Do not place the controller on oil, water, or soil,
or in a place that can be heated to a high
00-38 PC360LC-10
temperature even for a short period of time.

(Place it on a suitable dry stand.)
• Precautions when performing arc welding

When performing arc welding on the machine
body, disconnect all the wiring harness
connectors connected to the controller. Put the
arc welding ground to the place close to the
welding point.
Precautions for troubleshooting electrical

circuits
• Be sure to turn the starting switch to the "OFF"
position before disconnecting or connecting the
connectors.
• Before performing troubleshooting, check all the
related connectors for loose connection.
a Check the related connectors for their
performance by disconnecting and
connecting them several times.
• Be sure to connect all the disconnected
connectors before proceeding to the next step.
a If the starting switch is turned to the "ON"
position with the connectors disconnected,
the failure which is not related to the part
which is actually failed.
• When performing the troubleshooting for the
circuit (measurement of voltage, resistance,
continuity, current, etc.), shake the related wiring
harnesses and connectors several times and
check that the multimeter reading does not
change.
a If there is any value change on the
multimeter, there may be a defective contact
in the circuit.
PC360LC-10 00-39
How to read electric wire code (ALL-E500-030-P-00-A)

(Rev. 2012/10)
• In the electrical circuit diagram, material, thickness and color of each electric wire are indicated by
symbols. The wire code is helpful in understanding the electrical circuit diagram.
Example) AEX 0.85 L: Indicates blue, heat-resistant, low-voltage wire for automobile, having nominal No. of
0.85
Indicates type of wire by symbol.
Type, symbol, and material of wire are shown in Table 1.
AEX
(Since the use of AV and AVS wires depends on size (nominal No.), their symbols are not
indicated on the diagram.)
Indicates size of wire by nominal No.
0.85
Size (Nominal No.) is shown in Table 2.
Indicates color of wire by color code.
L
Color codes are shown in Table 3.
Type, symbol, and material

• AV and AVS are different in thickness and outside diameter of the coating. CAVC has a circular
compressed conductor. It differs from AV and AVS in the outside diameter of conductor and thickness of
the coating. And AEX is similar to AV in thickness and outside diameter of the coating but different from AV
and AVS in material of the coating.
(Table 1)
Temperature
Type Sym- Conductor Example of use
Insulator material range (°C) in
bol material
use
Low-voltage For large current wiring
wire for AV
automobile (nominal No. 5 and above)
Thin-cover
low-voltage
General wiring
wire for AVS
automobile (nominal No. 3 and lower)
Soft polyvinyl chloride -30 to +60
(Type 1) Annealed
Thin-cover copper for
low-voltage electric For mid- to small-size
wire for CAVS appliance excavators
automobile (nominal No. 1.25 and lower)
(Type 2)
Heat- General wiring for extremely
resistant low- Heat-resistant cross cold weather specification
voltage wire AEX linked polyethylene -50 to +110
for Wiring at high ambient
automobile temperature place
00-40 PC360LC-10
Dimensions
(Table 2)
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5
Number of
strands/ 20/ 30/ 11/ 50/ 16/ 37/ 26/ 58/ 41/ 65/
7/0.32
Diameter of 0.18 0.18 0.32 0.18 0.32 0.26 0.32 0.26 0.32 0.32
strand
Conductor Cross-
sectional 0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23
area (mm2)
d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0
AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 —
Coating D
AV Standard — — — — — — — 4.6
AEX Standard 2.0 2.2 2.7 3.0 3.1 — 3.8 4.6
Nominal No. 8 15 20 30 40 50 60 85 100

Number of
strands/ 108/ 127/ 169/ 217/
50/0.45 84/0.45 41/0.80 70/0.80 85/0.80
Diameter of 0.80 0.80 0.80 0.80
strand
Conductor Cross-
sectional 7.95 13.36 20.61 35.19 42.73 54.29 63.84 84.96 109.1
area (mm2)
d (approx.) 3.7 4.8 6.0 8.0 8.6 9.8 10.4 12.0 13.6
AVS Standard — — — — — — — — —
Coating D
AV Standard 5.5 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
AEX Standard 5.3 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
Nominal No. 0.5f 0.5 0.75f 0.85 1.25f 1.25

Number of
strands/ 7/round 11/round 16/round
— — —
Diameter of compression compression compression
strand
Conductor Cross-
sectional — 0.56 — 0.88 — 1.29
area (mm2)
d (approx.) — 0.9 — 1.1 — 1.4
Coating D
CAVS Standard — 1.6 — 1.8 — 2.1
a "f" of nominal No. denotes "flexible".
PC360LC-10 00-41
Color codes table

(Table 3)
Color Code Color of wire Color Code Color of wire
B Black LgW Light green & White
Br Brown LgY Light green & Yellow
BrB Brown & Black LR Blue & Red
BrR Brown & Red LW Blue & White
BrW Brown & White LY Blue & Yellow
BrY Brown & Yellow O Orange
Ch Charcoal P Pink
Dg Dark green R Red
G Green RB Red & Black
GB Green & Black RG Red & Green
GL Green & Blue RL Red & Blue
Gr Gray RW Red & White
GR Green & Red RY Red & Yellow
GW Green & White Sb Sky Blue
GY Green & Yellow Y Yellow
L Blue YB Yellow & Black
LB Blue & Black YG Yellow & Green
Lg Light green YL Yellow & Blue
LgB Light green & Black YR Yellow & Red
LgR Light green & Red YW Yellow & White
a Remarks: In a color code consisting of 2 colors, the first color is the color of the background and the
second color is the color of the marking.
Examples)
GW means that the background is "Green" and marking is "White".
Types of circuits and color codes

Type of wire AVS, AV, CAVS AEX
Charge R WG — — — — R —
Ground B — — — — — B —
Start R — — — — — R —
Light RW RB RY RG RL — D —
Instrument Y YR YB YG YL YW Y Gr
Signal G GW GR GY GB GL G Br
L LW LR LY LB — L —
Type of — — —
Br BrW BrR BrY BrB
circuit
Lg LgR LgY LgB LgW — — —
O — — — — — — —
Others Gr — — — — — — —
P — — — — — — —
Sb — — — — — — —
Dg — — — — — — —
Ch — — — — — — —
00-42 PC360LC-10
Precautions when performing operation (ALL-1160-927-A-00-A)
(Rev. 2012/11)
• When performing "testing and adjusting" of the machine, "removal and installation" and "disassembly and
assembly" of the components, observe the following general cautions.
Precautions for removal and disassembly work

• If the cooling water contains coolant, dispose of it correctly as chemicals. Do not drain it to the sewage
rashly.
• After disconnecting the hoses or tubes, plug them to prevent dirt or dust from entering.
• When draining oil, prepare a container with sufficient capacity.
• Check the match marks which indicate the installing position, and put match marks on the places where
they seem necessary before removal of the components to prevent any mistake when assembling.
• To prevent any excessive force from being applied to the wiring, always hold the connectors when
disconnecting the connectors. Do not pull the wires.
• Attach the tags to wires and hoses to show their installing positions to prevent any mistake when
installing.
• Check the number and thickness of the shims, and keep them in a safe place.
• When hoisting the components, prepare the slings with sufficient strength.
• When using forcing screws to remove any component, tighten the forcing screws uniformly and
alternately.
• Before removing any component, clean the surrounding area and cover the component to prevent any
foreign material from entering after removal.
• After disconnecting the piping or removing a pipe joint, install the following plugs.
a The O-rings in the table are emergency parts used for disassembly or transportation of the machine.
When assembling, confirm the part numbers in the parts book and use the parts conforming to the
using condition.
Disconnection of face seal type hoses and tubes
Hose side Pipe joint side

Nominal No. O-ring (3)
Plug (1) Nut (2)
02 07376-70210 02789-00210 02896-11008
03 07376-70315 02789-00315 02896-11009
04 07376-70422 02789-00422 02896-11012
05 07376-70522 02789-00522 02896-11015
06 07376-70628 02789-00628 02896-11018
PC360LC-10 00-43
Disconnection of taper seal type hoses and tubes
Hose side Pipe joint side

Nominal No.
Plug (1) Nut (2)
02 07376-50210 07222-00210
03 07376-50315 07222-00312
04 07376-50422 07222-00414
05 07376-50522 07222-00515
06 07376-50628 07222-00616
10 07376-51034 07222-01018
12 07376-51234 07222-01219
14 07376-51443 07222-01422
Disconnection of split flange type hoses and tubes
No- Bolt pitch (mm) Hose side Tube side

minal Split flange Sleeve head O-ring (4) Bolt (5) Washer (6)
a b Flange (1)
No. (2) (3)
07379- 01010-
04 38.1 17.5 07371-30400 07378-10400 07000-12021 01643-50823
00400 80825
07379- 01010-
05 42.9 19.8 07371-30500 07378-10500 07000-13022 01643-50823
00500 80830
07379- 07372-
06 47.6 22.2 07371-30640 07378-10600 07000-13025 01643-51032
00640 51035
07379- 07372-
10 52.4 26.2 07371-31049 07378-11000 07000-13032 01643-51032
01044 51035
07379- 07372-
58.7 30.2 07371-31255 07378-11200 07000-13038 01643-51032
01250 51035
12
07379- 01010-
66.7 31.8 07371-51260 07378-11210 07000-13038 01643-51232
01260 81245
07379- 07372-
14 69.9 35.8 07371-31465 07378-11400 07000-13048 01643-51232
01460 51240
00-44 PC360LC-10
No- Bolt pitch (mm) Hose side Tube side

minal Split flange Sleeve head O-ring (4) Bolt (5) Washer (6)
a b Flange (1)
No. (2) (3)
07379- 01010-
79.4 36.5 07371-51470 07378-11410 07000-13048 01643-31445
01470 81455
07379- 07372-
77.8 42.8 07371-32076 07378-12000 07000-12060 01643-51232
02071 51240
20
07379- 01010-
96.8 44.5 07371-52080 07378-12010 07000-12060 01643-31845
02080 81865
07379- 07372-
24 88.9 50.8 07371-12484 07378-12400 07000-12070 01643-51232
02484 51240
07379- 07372-
30 106.4 62 07371-13010 07378-13000 07000-12085 01643-51645
03010 51650
07372-
34 120.6 69.8 07379-03411 07371-13411 07378-13400 07000-12100 01643-51645
51650
07379- 07372-
40 130.2 77.8 07371-14012 07378-14000 07000-12110 01643-51645
04012 51650
07372-
50 152.4 92 07379-05011 07371-15011 07378-15000 07000-12135 01643-51645
51655
Removal of pipe joints of O-ring boss type
Nominal No. Plug (1) O-ring (2)

08 07040-10807 07002-10823
10 07040-11007 07002-11023
12 07040-11209 07002-11223
14 07040-11409 07002-11423
16 07040-11612 07002-11623
18 07040-11812 07002-11823
20 07040-12012 07002-12034
24 07040-12412 07002-12434
30 07041-13012 07002-13034
33 07040-13316 07002-13334
36 07041-13612 07002-13634
42 07040-14220 07002-14234
52 07040-15223 07002-15234
Removal of pipe joints of taper pipe thread type
PC360LC-10 00-45
Nominal Plug (1)

Nominal No.
thread size Square head type (A) Hexagonal socket head (B)
01 R 1/ 8 07042-00108 07043-00108
02 R 1/ 4 07042-00211 07043-00211
03 R 3/ 8 07042-00312 07043-00312
04 R 1/ 2 07042-00415 07043-00415
06 R 3/ 4 07042-00617 07043-00617
10 R1 07042-01019 07043-01019
12 R1 1/4 07042-01222 07043-01222
14 R1 1/2 07042-01422 07043-01422
20 R2 07042-02026 07043-02026
Precautions for installation and assembly work

• Tighten the bolts and nuts (sleeve nuts) to the specified torque (KES), unless otherwise specified.
• Install the hoses without twist and interference, and securely fasten the clamps located in-between if they
are.
• Replace all of the gaskets, O-rings, cotter pins, and lock plates with new parts.
• Bend the cotter pins and lock plates securely.
• When applying adhesive, clean and degrease the part, and apply 2 to 3 drops of adhesive to the threaded
portion.
• When applying liquid gasket, clean and degrease the surface, and apply it uniformly after making sure that
the surface is free from dirt or damage.
• Clean all of the parts, and repair any damage, dents, burrs, or rust found on them.
• Coat the rotating parts and sliding parts with engine oil.
• Coat the surfaces of the press-fitting parts with molybdenum disulfide lubricant (LM-P).
• After installing the snap ring, check that the snap ring is settled in the ring groove completely.
• When connecting wiring harness connectors, clean the connectors to remove oil, dirt, or water, then
connect them securely.
• Use the eye bolts with no fatigue and deformation and screw them in securely. Match the directions of the
eyes and the hook.
• When installing split flanges, tighten the bolts uniformly and alternately to prevent excessive tightening on
one side.
• As a rule, apply liquid gasket (LG-5) or liquid sealant (LS-2) to the threaded portion of each taper male
screws which receives pressure.
However, if the threaded portion is difficult to degrease, you may use a seal tape.
• When winding a seal tape onto a right-handed taper male screw, wind it clockwise in the advancing
direction of the threads, seeing from the screw end and starting at the third thread.
a If you wind the seal tape in the opposite direction, it becomes loose and comes off or its end part is
pushed out, and that can cause oil leakage.
00-46 PC360LC-10
a When the hydraulic cylinder is used for the first time after reassembly of the hydraulic equipment such as
the hydraulic cylinder, pump, etc. and piping after removing them for repair, be sure to perform air bleeding
of the hydraulic circuit according to the following procedure.
1. Start and run the engine at low idle.
2. Repeat the operation to extend and retract each cylinder of the work equipment to approximately 100
mm before the stroke end four to five times.
3. Operate the hydraulic cylinder 3 to 4 times to the end of its stroke.
a After the completion of repair and when operating the machine which is stored long term, perform the air
bleeding with the same procedure as the one described above.
Precautions at the time of completing work

Refilling of coolant, oil and grease
• When the coolant is drained, tighten the drain valve securely, then refill the coolant reservoir with the
coolant Komatsu recommends to the specified level. Start the engine to circulate the coolant in the piping,
and add the coolant to the specified level again.
• When the hydraulic components are removed and installed, refill the oil reservoir with the oil Komatsu
recommends to the specified level. Start the engine to circulate the oil in the piping, and add the oil to the
specified level again.
• If the hydraulic piping or hydraulic equipment is removed, be sure to bleed air from the system after
rebuilding the parts, by referring to "Testing and adjusting".
• Supply the specified amount of grease to the work equipment parts.
Testing installed condition of cylinder heads and manifolds
• Check the cylinder head and intake and exhaust manifold mountings for looseness.
• If any bolt is loose, retighten it.
a For the tightening torques, see the "Disassembly and assembly".
Testing of engine piping for damage and looseness
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints
Intake and exhaust for air suction and exhaust gas leakage.
system
If any part is loosely installed or damaged, retighten the bolts or repair the parts.
Cooling system for water leakage.
Fuel system for fuel leakage.
Check of KDPF or muffler and exhaust pipe for damage and looseness
• Visually check the KDPF or muffler, exhaust pipe and their mounting parts for a crack and damage. If any
part is damaged, replace it.
• Check the mounting bolts, nuts, and clamps of the KDPF or muffler, exhaust pipe and their mounting parts
for looseness.
If any part is loosely installed, retighten the bolts.
Check of KDPF or muffler function
• Check the KDPF or the muffler for unusual noise comparing to the noise when they are new.
If any unusual noise is heard, repair KDPF or muffler, referring to "Troubleshooting" and "Disassembly and
assembly".
PC360LC-10 00-47
Practical use of KOMTRAX (ALL-Q210-13V-K-00-A)

(Rev. 2012/10)
KOMTRAX system transmits various machine information by use of the radio communication and KOMTRAX
operator can refer this information in the office and provide various services to the customers.
When KOMTRAX is installed on the machine, the machine information can be checked through the
KOMTRAX system and the testing and troubleshooting can be performed efficiently.
(KOMTRAX may not be installed on the machine in some countries or areas.)
Merit of using KOMTRAX

• The working place of the machine can be checked in the map on PC.
• Operation information such as service meter reading, operating hours, fuel consumption, occurred caution
and failure code can be checked.
• The hours used and replacement time of consumable parts of the machine such as fuel filter, hydraulic oil
filter, hydraulic oil and engine oil can be checked.
• The information of machine working condition (idling time, traveling time, digging time, relieving time, etc.)
can be checked and the machine operating condition can be presumed with these information.
• Various reports such as "Fuel saving operation support", "Summary of operation", etc. can be generated
and utilized as an advice tool for the user and operator.
How to use KOMTRAX practically

With KOMTRAX, following support activities will be available.
1. Quick response to sudden request of repair
1) When receiving a repair request from a user, check the displayed caution and failure code, etc. through
KOMTRAX.
2) Arrange the necessary tools, replacement parts, etc, immediately in accordance with the displayed
failure code.
3) By using the map of KOMTRAX, find the location of the failed machine and visit the customer there.
2. Proactive maintenance
1) Check the service summary screen of KOMTRAX, and find the machine which has high priority failure
code indicated by a red or yellow flag.
2) Check the condition of the machine with the customer and make a plan to visit.
3) Arrange necessary tools, replacement parts, etc, immediately in accordance with the displayed failure
code.
3. Practice of periodic maintenance and periodic inspection service
1) Check the service summary screen of KOMTRAX, and find the machine of which the usage limits for
the consumable parts indicated by red flags are over.
2) Submit an estimate sheet for the consumable parts to be replaced and the labor cost for the
replacement work to the customer.
3) Propose the periodic inspection (PM clinic, etc.) according to the service meter reading.
How to operate KOMTRAX

For the operating method of each screen of KOMTRAX, see "KOMTRAX basic operation manual".
00-48 PC360LC-10
Standard tightening torque table (ALL-M140-03B-P-01-A)
(Rev. 2012/10)
Table of tightening torque for bolts and nuts

Unless otherwise specified, tighten the metric bolts and nuts to the torque shown in the table below.
Thread diameter Width across flats

Tightening torque (Nm {kgm})
(mm) (mm)
10
6 11.8 to 14.7 {1.2 to 1.5}
(*2) 10
13
8 27 to 34 {2.8 to 3.5}
(*2) 12
17
10 59 to 74 {6.0 to 7.5}
(*1, *2) 14
19
12 98 to 123 {10.0 to 12.5}
(*1, *2) 17
14 22 157 to 196 {16 to 20}
24
16 245 to 309 {25 to 31.5}
(*1) 22
18 27 343 to 427 {35 to 43.5}
20 30 490 to 608 {50 to 62}
22 32 662 to 829 {67.5 to 84.5}
24 36 824 to 1,030 {84 to 105}
27 41 1,180 to 1,470 {120 to 150}
30 46 1,520 to 1,910 {155 to 195}
33 50 1,960 to 2,450 {200 to 250}
36 55 2,450 to 3,040 {250 to 310}
39 60 2,890 to 3,630 {295 to 370}
*1: Split flange bolt.
*2: Flanged bolt.
PC360LC-10 00-49
a Tighten the following flanged bolt on which "7" is stamped on its top to the tightening torque shown in the
following table.
Thread diameter Width across flats

Tightening torque (Nm {kgm})
(mm) (mm)
6 10 5.9 to 9.8 {0.6 to 1.0}
8 12 13.7 to 23.5 {1.4 to 2.4}
10 14 34.3 to 46.1 {3.5 to 4.7}
12 17 74.5 to 90.2 {7.6 to 9.2}
Unless otherwise specified, tighten the unified coarse threaded bolts and nuts to the torque shown in the table
below.
Type of bolt A B
Nominal No. - Tightening torque (Nm {kgm}) Tightening torque (Nm {kgm})
threads per inch,
type of thread Range Target Range Target
1/4-20UNC 9.8 to 14.7 {1 to 1.5} 12.7 {1.3} 2.9 to 3.9 {0.3 to 0.4} 3.43 {0.35}
5/16-18UNC 24.5 to 34.3 {2.5 to 3.5} 29.4 {3} 6.9 to 8.8 {0.7 to 0.9} 7.8 {0.8}
3/8-16UNC 44.1 to 58.8 {4.5 to 6} 52.0 {5.3} 9.8 to 14.7 {1 to 1.5} 11.8 {1.2}
7/16-14UNC 73.5 to 98.1 {7.5 to 10} 86.3 {8.8} 19.6 to 24.5 {2 to 2.5} 21.6 {2.2}
1/2-13UNC 108 to 147 {11 to 15} 127 {13} 29.4 to 39.2 {3 to 4} 34.3 {3.5}
9/16-12UNC 157 to 216 {16 to 22} 186 {19} 44.1 to 58.8 {4.5 to 6} 51.0 {5.2}
5/8-11UNC 226 to 294 {23 to 30} 265 {27} 63.7 to 83.4 {6.5 to 8.5} 68.6 {7}
3/4-10UNC 392 to 530 {40 to 54} 461 {47} 108 to 147 {11 to 15} 127 {13}
7/8-9UNC 637 to 853 {65 to 87} 745 {76} 177 to 235 {18 to 24} 206 {21}
1-8UNC 883 to 1,196 {90 to 122} 1,040 {106} 245 to 333 {25 to 34} 284 {29}
1 1/8-7UNC 1,187 to 1,608 {121 to 164} 1,393 {142} 333 to 451 {34 to 46} 392 {40}
1 1/4-7UNC 1,598 to 2,157 {163 to 220} 1,873 {191} 451 to 608 {46 to 62} 530 {54}
1 1/2-6UNC 2,354 to 3,177 {240 to 324} 2,765 {282} 657 to 892 {67 to 91} 775 {79}
00-50 PC360LC-10
Unless otherwise specified, tighten the unified fine threaded bolts and nuts to the torque shown in the table
below.
Type of bolt A B
Nominal No. - Tightening torque (Nm {kgm}) Tightening torque (Nm {kgm})
threads per inch,
type of thread Range Target Range Target
1/4-28UNF 14.7 to 19.6 {1.5 to 2} 17.7 {1.8} 3.9 to 4.9 {0.4 to 0.5} 4.41 {0.45}
5/16-24UNF 34.3 to 39.2 {3.5 to 4} 37.3 {3.8} 7.8 to 9.8 {0.8 to 1} 8.8 {0.9}
3/8-24UNF 53.9 to 68.6 {5.5 to 7} 61.8 {6.3} 14.7 to 19.6 {1.5 to 2} 16.7 {1.7}
7/16-20UNF 83.4 to 108 {8.5 to 11} 96.1 {9.8} 24.5 to 29.4 {2.5 to 3} 26.5 {2.7}
1/2-20UNF 127 to 167 {13 to 17} 147 {15} 34.3 to 49.0 {3.5 to 5} 41.2 {4.2}
9/16-18UNF 186 to 245 {19 to 25} 216 {22} 49.0 to 68.6 {5 to 7} 58.6 {6}
5/8-18UNF 255 to 343 {26 to 35} 294 {30} 73.5 to 98.1 {7.5 to 10} 83.4 {8.5}
3/4-16UNF 441 to 598 {45 to 61} 520 {53} 127 to 167 {13 to 17} 147 {15}
7/8-14UNF 716 to 961 {73 to 98} 843 {86} 196 to 265 {20 to 27} 226 {23}
1-14UNF 1,020 to 1,373 {104 to 140} 1,196 {122} 284 to 382 {29 to 39} 333 {34}
1 1/8-12UNF 1,353 to 1,844 {138 to 188} 1,598 {163} 382 to 520 {39 to 53} 451 {46}
1 1/4-12UNF 1,804 to 2,432 {184 to 248} 2,118 {216} 510 to 686 {52 to 70} 598 {61}
1 1/2-12UNF 2,707 to 3,658 {276 to 373} 3,177 {324} 765 to 1,030 {78 to 105} 892 {91}
Table of tightening torque for O-ring boss piping joints

a Unless otherwise specified, tighten the pipe joint for O-ring boss to the torque shown in the table below.
Thread Width Tightening torque (Nm {kgm})

Nominal No. diameter across flats
(mm) (mm) Range Target
02 14 Varies 35 to 63 {3.5 to 6.5} 44 {4.5}
— 18 depending 59 to 98 {6.0 to 10.0} 78 {8.0}
03, 04 20 on type of 84 to 132 {8.5 to 13.5} 103 {10.5}
05, 06 24 connector. 128 to 186 {13.0 to 19.0} 157 {16.0}
PC360LC-10 00-51

10, 12 33 363 to 480 {37.0 to 49.0} 422 {43.0}
14 42 746 to 1,010 {76.0 to 103} 883 {90.0}
Table of tightening torque for O-ring boss plugs

a Unless otherwise specified, tighten the plug for O-ring boss to the torque shown in the table below.

08 8 14 5.88 to 8.82 {0.6 to 0.9} 7.35 {0.75}
10 10 17 9.8 to 12.74 {1.0 to 1.3} 11.27 {1.15}
12 12 19 14.7 to 19.6 {1.5 to 2.0} 17.64 {1.8}
14 14 22 19.6 to 24.5 {2.0 to 2.5} 22.54 {2.3}
16 16 24 24.5 to 34.3 {2.5 to 3.5} 29.4 {3.0}
18 18 27 34.3 to 44.1 {3.5 to 4.5} 39.2 {4.0}
20 20 30 44.1 to 53.9 {4.5 to 5.5} 49.0 {5.0}
24 24 32 58.8 to 78.4 {6.0 to 8.0} 68.6 {7.0}
30 30 32 93.1 to 122.5 {9.5 to 12.5} 107.8 {11.0}
33 33 — 107.8 to 147.0 {11.0 to 15.0} 127.4 {13.0}
36 36 36 127.4 to 176.4 {13.0 to 18.0} 151.9 {15.5}
42 42 — 181.3 to 240.1 {18.5 to 24.5} 210.7 {21.5}
52 52 — 274.4 to 367.5 {28.0 to 37.5} 323.4 {33.0}
Table of tightening torque for hose (taper seal type and face seal type)
a Unless otherwise specified, tighten the hose fittings (taper seal type and face seal type) to the torque
shown in the table below.
a The table is applied to the threads coated with engine oil (wet threads)
00-52 PC360LC-10
Tightening torque (Nm {kgm}) Taper seal Face seal

Width
Nominal across Nominal No. - Thread root
No. of flats Thread size threads per diameter
Range Target
hose (mm) (mm) inch, type of (mm)
thread (reference)
34 to 54 {3.5 to 5.5} 44 {4.5} — 9/16-18UN 14.3
02 19
34 to 63 {3.5 to 6.5} 44 {4.5} 14 — —
22 54 to 93 {5.5 to 9.5} 74 {7.5} — 11/16-16UN 17.5
03
24 59 to 98 {6.0 to 10.0} 78 {8.0} 18 — —
04 27 84 to 132 {8.5 to 13.5} 103 {10.5} 22 13 /16-16UN 20.6
05 32 128 to 186 {13.0 to 19.0} 157 {16.0} 24 1 -14UNS 25.4
06 36 177 to 245 {18.0 to 25.0} 216 {22.0} 30 1 3/16-12UN 30.2
(10) 41 177 to 245 {18.0 to 25.0} 216 {22.0} 33 — —
(12) 46 197 to 294 {20.0 to 30.0} 245 {25.0} 36 — —
(14) 55 246 to 343 {25.0 to 35.0} 294 {30.0} 42 — —
Table of tightening torque for face seal joints

a The tightening torque table below applies to the seal joint (sleeve nut type)
a The table is applied to the threads coated with engine oil (wet threads).
Tightening torque (Nm {kgm}) Face seal

Outer Width
diameter of across flats Nominal No. - Thread root
pipe (mm) (mm) Range Target threads per inch, diameter (mm)
type of thread (reference)
8 19 14 to 16 {1.4 to 1.6} 15 {1.5} 9/16-18UN 14.3
10 22 24 to 27 {2.4 to 2.7} 25.5 {2.6} 11/16-16UN 17.5
12 24 {27} 43 to 47 {4.4 to 4.8} 45 {4.6} 13/16-16UN 20.6
15 {16} 30 {32} 60 to 68 {6.1 to 6.8} 64 {6.5} 1 -14UNS 25.4
22 {20} 36 90 to 95 {9.2 to 9.7} 92.5 {9.4} 1 3/16-12UN 30.2
Reference: The face seal joint of the dimension in ( ) is also used, depending on the specification.
Tightening torque table for bolts and nuts on 102,107 and 114 series engines
a Unless otherwise specified, tighten the metric threads bolts and nuts used on the 102, 107 and 114 series
engines to the torques shown in the table below.
Thread diameter (mm) Tightening torque (Nm {kgm})
6 10 ± 2 {1.02 ± 0.20}
8 24 ± 4 {2.45 ± 0.41}
10 43 ± 6 {4.38 ± 0.61}
12 77 ± 12 {7.85 ± 1.22}
14 —
PC360LC-10 00-53
Tightening torque table for 102, 107, and 114 series engines (joint bolts)
a Unless otherwise specified, tighten the metric joint bolts used on the 102, 107, and 114 series engines to
the torque shown in the table below.
Thread diameter (mm) Tightening torque (Nm {kgm})

6 8 ± 2 {0.81 ± 0.20}
8 10 ± 2 {1.02 ± 0.20}
10 12 ± 2 {1.22 ± 0.20}
12 24 ± 4 {2.45 ± 0.41}
14 36 ± 5 {3.67 ± 0.51}
Tightening torque table for tapered screws on 102,107, and 114 series engines (National taper pipe
thread (NPT))
a Unless otherwise specified, tighten the National taper pipe threaded (NPT) screws used on the 102, 107,
and 114 series engines to the torques shown in the table below.
Material of female screw In cast iron or steel In aluminum
Nominal thread size Tightening torque (Nm {kgm}) Tightening torque (Nm {kgm})
1/16 15 ± 2 {1.53 ± 0.20} 5 ± 1 {0.51 ± 0.10}
1/ 8 20 ± 2 {2.04 ± 0.20 15 ± 2 {1.53 ± 0.20}
1/ 4 25 ± 3 {2.55 ± 0.31} 20 ± 2 {2.04 ± 0.20}
3/ 8 35 ± 4 {3.57 ± 0.41} 25 ± 3 {2.55 ± 0.31}
1/ 2 55 ± 6 {5.61 ± 0.61} 35 ± 4 {3.57 ± 0.41}
3/ 4 75 ± 8 {7.65 ± 0.82} 45 ± 5 {4.59 ± 0.51}
00-54 PC360LC-10
List of abbreviation (ALL-0360-005-A-00-A)

(Rev. 2012/11)
• This list of abbreviations includes the abbreviations used in the text of the shop manual for parts,
components, and functions whose meaning is not immediately clear. The spelling is given in full with an
outline of the meaning.
• Abbreviations that are used in general society may not be included.
• Special abbreviations which appear infrequently are noted in the text (marked with a).
• This list of abbreviations consists of 2 parts. The first part is a list of the abbreviations used in the text of
the manual, and the second part is a list of the abbreviations used in the circuit diagrams.
List of abbreviations used in the shop manual

Purpose of use (major
Abbrevia- Actual word spelled applicable machine (*), or Explanation
tion out equipment/device)
Function with which when the tires skid
Anti-skid Brake Travel and brake (wheels stop rotating), the brakes are
ABS System released, and when the wheels start to rotate,
(HD, HM)
the brakes are applied again.
Automatic Idling
AISS Engine Automatic setting function of idle speed
Setting System
Function that a lever can perform the steering
Advanced Joystick Steering operations, shifting gear speed operation and
AJSS Steering System changing direction operation instead of a
(WA)
steering wheel.
Function that the retarder works automatically
Automatic Retarder Travel and brake with a certain braking force when the
ARAC
Accelerator Control (HD, HM) accelerator pedal is released while the
machine travels downhill.
Function that the retarder works automatically
with a certain braking force so that the
Automatic Retarder Travel and brake machine travels with the speed not exceeding
ARSC Speed Control (HD, HM) the speed set by the operator when the
accelerator pedal is released while the
machine travels downhill.
Function with which, when the rear wheels
Automatic Spin Travel and brake spin on soft ground surfaces, this function
ASR Regulator (HD, HM) automatically uses the optimum braking force
to drive both wheels.
A device that can be fixed onto a machine in
ATT Attachment Work equipment
order to enable it to do different jobs.
Brake Valve that bypasses part of the brake cooling
Brake cooling oil oil to reduce the load on the hydraulic pump
BCV
control valve (HD) when the retarder is not being used.
Controller Area Communication and One of communication standards that is used
CAN
Network electronic control in the network on the machine
Crankcase Depression Regulator valve that is installed to the KCCV
CDR Engine ventilator It is not used independently and
Regulator
described CDR valve.
System that can simultaneously actuate
Closed-center Load multiple actuators regardless of the load
CLSS Oil pressure
Sensing System (provides better combined operation
comparing to OLSS).
Function to maintain optimum fuel injection
amount and fuel injection timing by using
CRI Common Rail Injection Engine
engine controller to perform electronic control
of supply pump, common rail, and injector.
Electronic control device that uses the signals
Electronic Control from the sensors on the machine to indicate
ECM Electronic control system
Module the optimum actuation to the actuators .
(Same as ECU)
PC360LC-10 00-55

Transmission Proportional electromagnetic valve that
Electronic Control
ECMV gradually increases oil pressure to engage
Modulation Valve (D, HD, WA, etc.)
clutch and reduces transmission shock.
System that ensures smooth high-speed
Electronically Travel travel by using hydraulic spring effect of
ECSS Controlled Suspension
(WA) accumulator to absorb vibration of machine
System
during travel
Electronic control device that uses the signals
from the sensors on the machine to indicate
ECU Electronic Control Unit Electronic control system the optimum actuation to the actuators .
(Same as ECM)
Function to recirculate part of exhaust gas to
Exhaust Gas Engine combustion chamber in order to reduce
EGR
Recirculation combustion temperature and to control
emission of NOx.
Equipment System that allows data (filter, oil replacement
Management interval, malfunctions on machine, failure
EMMS Machine monitor
Monitoring System code, and failure history) from each sensor on
the machine to be checked on monitor.
Electromagnetic Electromagnetic proportional control
EPC Oil pressure Mechanism that actuator works in proportion
Proportional Control
to current
Structure that protects operator's head from
Falling Object Cab and canopy falling objects. (Structure to protect operator)
FOPS
Protective Structure
Performance standardized in ISO 3449
Forward-Neutral- Operation
F-N-R Forward - NEUTRAL - REVERSE
Reverse
Communication Global Positioning System Satellite
Global Positioning
GPS System (KOMTRAX ､KOMTRAX positioning system that is used to determine
Plus) the current location on the earth
Steering function that uses a combination of
Hydrostatic Steering Steering hydraulic motor and bevel shaft to control
HSS System difference in travel speed of right and left
(D) tracks to turn machine without using steering
clutch.
Hydraulic transmission system that uses a
Hydro Static Transmission combination of hydraulic pump and hydraulic
HST motor to shift gear steplessly without using
Transmission (D, WA)
gears.
Valve that adjusts fuel intake amount at inlet
Inlet Metering Actuator Engine port of pump in order to control fuel discharge
IMA
amount of supply pump. Same meaning as
IMV
Valve adjusting fuel intake amount at inlet port
IMV Inlet Metering Valve Engine of pump in order to control fuel discharge
amount of supply pump. Described IMV (IMA)
This mechanism separates oil in blowby gas
Komatsu Closed Engine and returns it to the intake side to afterburn it
KCCV
Crankcase Ventilation there. It primarily consists of filters.
Komatsu Catalyzed This filter captures soot in exhaust gas.
KCSF Engine
Soot Filter It is built in to KDPF.
The catalyst used for purifying exhaust gas.
Komatsu Diesel
KDOC Engine This is built in KDPF or assembled with the
Oxidation Catalyst
muffler.
This component contains KDOC (catalyst)
Komatsu Diesel Engine and KCSF (soot filter) for purifying exhaust
KDPF
Particulate Filter gas.
00-56 PC360LC-10

It is installed in place of the conventional
muffler.
Function that recovers the drive force of the
wheels by braking automatically with the
Komatsu Traction Travel and brake optimum force and at the same time activates
KTCS Control System the inter-axle differential lock when the wheels
(HM system)
idle while the machine travels on the soft
ground road.
Komatsu Variable
The turbocharger on which the cross-section
KVGT Geometry Engine
area of the exhaust passage is made variable.
Turbocharger
Liquid Display Image display equipment such
LCD Liquid Crystal Display Machine monitor as the monitor which assembles in the liquid
crystal element.
Light Emitting Diode Semi-conductor element
LED Light Emitting Diode Electronic parts that emits light when the voltage is applied in
the normal direction.
Local Interconnect Communication and One of communication standards that is used
LIN
Network electronic control in the network on the machine
Function that detects differential pressure of
LS Load Sensing Oil pressure pump and controls discharge amount
according to load.
Low Voltage Communication and One of communication standards that is used
LVDS Differential Signaling electronic control in the network on the machine
It means the intake air flow of the engine. It is
Engine not used independently but used together with
MAF Mass Air Flow
the sensor. The mass air flow sensor may be
called MAF sensor.
Service that allows transmission and
Multimedia Messaging reception of short messages consisting of
MMS Communication characters or voice or images between cell
Service
phones.
Device actuated to open electric or hydraulic
NC Normally Closed Electric and hydraulic circuits that are normally closed if not
actuated.
Device actuated to close electric or hydraulic
NO Normally Open Electric and hydraulic
circuits that are normally open if not actuated.
Open-center Load Hydraulic system that can operate multiple
OLSS Oil pressure actuators at the same time, regardless of the
Sensing System
load.
Pressure
PC Oil pressure A function used to correct oil pressure.
Compensation
System in which a controller instantly
Palm command control Steering analyses data from each lever, pedal, and
PCCS system dial, and performs optimum electronic control
(D)
of the engine and transmission.
Valve installed at inlet port of pump to adjust
Pre-stroke Control Engine fuel intake amount in order to control fuel
PCV
Valve discharge amount of supply pump.
Proportional pressure control Mechanism that
Proportional Pressure Oil pressure actuator works in proportion to hydraulic
PPC
Control pressure
Piston Pump and Oil pressure
PPM Piston pump and motor.
Motor (D, PC, etc.)
PTO Power Take Off Power transmission Power take-off mechanism
Power Tilt and power Work equipment Function that performs hydraulic control of the
PTP tilt and pitch of the bulldozer blade.
Pitch dozer (D)
PC360LC-10 00-57

Structure that protects operator fastening seat
belt from being crushed when machine tips
Roll-Over Protective Cab and canopy over (Structure to protect operator when
ROPS:
Structure machine tips over)
Performance standardized in ISO 3471
Abbreviation for "International system of units"
International unit
SI Unit Unit system that is employed worldwide, and
system
"one unit against one factor"
Actuator that moves a part with a movable iron
SOL Solenoid Electric core in the coil (solenoid), which is moved by
energizing the coil.
2-Way Valve Hydraulic and electric Solenoid valve that switches the direction of
TWV
flow.
Variable Flow Turbocharger variable in route of exhaust
VFT Engine
Turbocharger passage.
*1: Code for applicable machine family
D: Bulldozer
HD: Dump truck
HM: Articulated dump truck
PC: Hydraulic excavator
WA: Wheel loader
List of abbreviations used in the circuit diagrams
Abbreviation Actual word spelled out
A/C Air Conditioner
A/D Analogue-to-Digital
A/M Air Mix Damper
ACC Accessory
ADD Additional
AUX Auxiliary
BR Battery Relay
CW Clockwise
CCW Counter Clockwise
ECU Electronic Control Unit
ECM Electronic Control Module
ENG Engine
EXGND External Ground
F.G. Frame Ground
GND Ground
IMA Inlet Metering Actuator
NC No Connection
S/T
Steering
STRG
SIG Signal
SOL Solenoid
STD Standard
OPT
Option
OP
PRESS Pressure
SPEC Specification
SW Switch
TEMP Temperature
00-58 PC360LC-10
Abbreviation Actual word spelled out

T/C Torque Converter
T/M Transmission
PC360LC-10 00-59
Conversion table (ALL-2150-931-A-00-A)

(Rev. 2012/10)
Method of using the conversion table

• The unit conversion table enables the simple conversion in the figures between the different units. For
further details of the method of use of the conversion table, see the examples given below.
Example: Method of using the conversion table to convert a unit from millimeters to inches
Conversion of 55 mm into inches
1. Locate the number 50 in the vertical column at the left side, take this as (A), and then draw a horizontal
line from (A).
2. Locate the number 5 in the row across the top, take this as (B), then draw a vertical line down from (B).
3. Take the point where the 2 lines cross as (C). This point (C) gives the value when converting the unit from
millimeters to inches. Therefore, 55 mm = 2.165 in.
Conversion of 550 mm into inches
1. The number 550 does not appear in the table, so divide it by 10 (move the decimal point one place to the
left) to get 55 mm.
2. Then convert 55 mm to 2.165 in by the same procedure as above.
3. The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point
one place to the right) to get the original value. This gives 550 mm = 21.65 in. Therefore, 550 mm = 21.65
in.
Millimeters to inches
(B)
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
(C)
50 1.969 2.008 2.017 2.087 2.126 2.165 2.205 2.244 2.283 2.323
(A)
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.847 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
00-60 PC360LC-10
Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.847 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilograms to pounds
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
l to U.S. Gallons
1 l = 0.2642 U.S.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
PC360LC-10 00-61
l to U.K. Gallons
1 l = 0.21997 U.K.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.699 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
kgm to ft.lb
1 kgm = 7.233 ft.lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
00-62 PC360LC-10
kg/cm2 to lb/in22
1 kg/cm2 = 14.2233 lb/in22
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1,010 1,024 1,038 1,053 1,067 1,081 1,095 1,109 1,124
80 1,138 1,152 1,166 1,181 1,195 1,209 1,223 1,237 1,252 1,266
90 1,280 1,294 1,309 1,323 1,337 1,351 1,365 1,380 1,394 1,408
100 1,422 1,437 1,451 1,465 1,479 1,493 1,508 1,522 1,536 1,550
110 1,565 1,579 1,593 1,607 1,621 1,636 1,650 1,664 1,678 1,693
120 1,707 1,721 1,735 1,749 1,764 1,778 1,792 1,806 1,821 1,835
130 1,849 1,863 1,877 1,892 1,906 1,920 1,934 1,949 1,963 1,977
140 1,991 2,005 2,020 2,034 2,048 2,062 2,077 2,091 2,105 2,119
150 2,134 2,148 2,162 2,176 2,190 2,205 2,219 2,233 2,247 2,262
160 2,276 2,290 2,304 2,318 2,333 2,347 2,361 2,375 2,389 2,404
170 2,418 2,432 2,446 2,460 2,475 2,489 2,503 2,518 2,532 2,546
180 2,560 2,574 2,589 2,603 2,617 2,631 2,646 2,660 2,674 2,688
190 2,702 2,717 2,731 2,745 2,759 2,773 2,788 2,802 2,816 2,830
200 2,845 2,859 2,873 2,887 2,901 2,916 2,930 2,944 2,958 2,973
210 2,987 3,001 3,015 3,030 3,044 3,058 3,072 3,086 3,101 3,115
220 3,129 3,143 3,158 3,172 3,186 3,200 3,214 3,229 3,243 3,257
230 3,271 3,286 3,300 3,314 3,328 3,343 3,357 3,371 3,385 3,399
240 3,414 3,428 3,442 3,456 3,470 3,485 3,499 3,513 3,527 3,542
PC360LC-10 00-63
Temperature
Conversion of Fahrenheit to Celsius
• A simple way to convert a Fahrenheit temperature reading into a Celsius temperature reading or vice
versa is to see the number in the center column of the following table. The figures on the following table
show the temperatures in both Fahrenheit and Celsius.
• When converting from Fahrenheit to Celsius degrees, consider the center column to be a table of
Fahrenheit temperatures and read the corresponding Celsius temperature in the column at the left.
• When converting from Celsius to Fahrenheit degrees, consider the center column to be a table of Celsius
values, and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8°F
°C °F °C °F °C °F °C °F
-40.4 -40 -40.0 -11.7 11 51.8 7.8 46 114.8 27.2 81 177.8
-37.2 -35 -31.0 -11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
-34.4 -30 -22.0 -10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
-31.7 -25 -13.0 -10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
-28.9 -20 -4.0 -9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
-28.3 -19 -2.2 -8.9 16 60.8 10.6 51 123.8 30.0 86 186.8
-27.8 -18 -0.4 -8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
-27.2 -17 1.4 -7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
-26.7 -16 3.2 -7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
-26.1 -15 5.0 -6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
-25.6 -14 6.8 -6.1 21 69.8 13.3 56 132.8 32.8 91 195.8
-25.0 -13 8.6 -5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
-24.4 -12 10.4 -5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
-23.9 -11 12.2 -4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
-23.3 -10 14.0 -3.9 25 77.0 15.6 60 140.0 35.0 95 203.0
-22.8 -9 15.8 -3.3 26 78.8 16.1 61 141.8 35.6 96 204.8
-22.2 -8 17.6 -2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
-21.7 -7 19.4 -2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
-21.1 -6 21.2 -1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
-20.6 -5 23.0 -1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
-20.0 -4 24.8 -0.6 31 87.8 18.9 66 150.8 40.6 105 221.0
-19.4 -3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
-18.9 -2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
-18.3 -1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
-17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
-17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0
-16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
-16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
-15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
-15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
-14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0
-13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
-13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
-12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
-12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
00-64 PC360LC-10
SHOP MANUAL
HYDRAULIC EXCAVATOR
PC360LC-10
Model Serial Number
PC360LC-10 70001 and up
01 Specification
2 01 Specification
PC360LC-10 01-1
01 Specification
Table of contents
Table of contents (ALL-0310-002-A-00-A)

01 Specification................................................................................................................................. 01-1
Specifications............................................................................................................................. 01-3
Specification drawing ........................................................................................................... 01-3
Working range drawings ....................................................................................................... 01-4
Specifications ...................................................................................................................... 01-5
Weight table ........................................................................................................................ 01-8
Table of fuel, coolant and lubricants ..................................................................................... 01-10
01-2 PC360LC-10
01 Specification
Specification drawing
Specifications (ALL-2111-001-A-00-A)
Specification drawing (ALL-2110-001-A-00-A)
PC360LC-10 (PC300_10-2110-931-A-00-A)
Item Unit PC360LC-10

Machine weight kg 35,140
Bucket capacity m3 1.4
Engine model - Komatsu SAA6D114E-5 diesel engine
Engine rated horsepower
• SAE J1995(Gross) 202 {271}/1,950 {1,950}
kW{HP}/min-1
• ISO 14396 202 {271}/1,950 {1,950}
{rpm}
• ISO 9249/SAE J1349(Net) 192 {257}/1,950 {1,950}
A Overall length mm 11,145
Overall height (including grouser
B height) mm 3,285
C Overall width mm 3,440
D Shoe width mm 850
Cab height (including shoe grouser
E height) mm 3,160
F Tail swing radius mm 3,445
G Overall length of track mm 4,955
H Distance between tumbler centers mm 4,030
Handrail height (including grouser
I height) mm 3,255
J Min. ground clearance mm 498
Travel speed (Lo/Mi/Hi) km/h 3.2/4.5/5.5
Swing speed min-1 {rpm} 9.5 {9.5}
a The engine flywheel horsepower is indicated in the net value and gross value. Gross denotes the rated
output measured on the bare engine unit. While, net denotes the value measured of an engine under the
condition essentially the same as that when it is installed on machine.
PC360LC-10 01-3
01 Specification
Working range drawings
Working range drawings (ALL-2110-001-A-02-A)
PC360LC-10 (PC300_10-2110-931-A-01-A)
項目単位 PC360LC-10
A Max. digging reach mm 11,110
B Max. digging depth mm 7,380
C Max. digging height mm 10,210
D Max. vertical wall digging depth mm 6,480
E Max. dumping height mm 7,110
F Min. dumping height mm 2,640
Max. digging reach at ground mm 10,920
G
level
01-4 PC360LC-10
01 Specification
Specifications
Specifications (ALL-2111-001-A-01-A)
PC360LC-10 (PC300-2111-931-A-00-A)
Machine model PC360LC-10

Unit
Serial number 70001 and up
Bucket capacity m3 1.4
Machine weight kg 35,140
Performance
Working range
Max. digging depth mm 7,380
Max. vertical wall digging depth mm 6,480
Max. digging reach mm 11,100
Max. digging reach at ground level mm 10,920
Max. digging height mm 10,210
Max. dumping height mm 7,110
Max. digging force 211.8 {21,600}
kN {kg}
with power maximizing function (226.5 {23,100})
Swing speed min-1 {rpm} 9.5 {9.5}
Max. slope angle for swing deg. 18
Travel speed (Lo/Mi/Hi) km/h 3.2/4.5/5.5
Gradeability deg. 35
Ground pressure (standard shoe) kPa {kg/cm2} 46.2 {0.47}
Dimensions
Overall length mm 11,145
Overall width mm 3,440
Overall height (for transport) (*1) mm 3,290
Ground clearance of upper structure (*2) mm 1,185
Min. ground clearance mm 498
Tail swing radius mm 3,445
Min. swing radius of work equipment mm 4,310
Maximum height of work equipment in
mm 8,520
min. swing radius posture (*2)
Overall width of track mm 3,440
Overall length of track mm 4,955
Track gauge mm 2,590
Distance between tumbler centers mm 4,030
Cab height (*1) mm 3,160
Width of standard shoe mm 850
*1: Grouser height (36 mm) included.
*2: Grouser height (36 mm) not included.
PC360LC-10 01-5
01 Specification
Specifications

Unit
Engine
Model - SAA6D114E-5
4-cycle, water-cooled, in-line vertical, direct
Type - injection type with turbocharger and air-cooled
aftercooler
Number of cylinders – bore x stroke mm 6-114 × 144.5
Total piston displacement l {cc} 8.85 {8,850}
Performance
Rated horsepower
• SAE J1995 (Gross) 202 {271}/1,950 {1,950}
kW{HP}/min-1
• ISO 14396 202 {271}/1,950 {1,950}
{rpm}
• ISO 9249/SAE J1349 (Net) 192 {257}/1,950 {1,950}
Nm{kgm}/min-1
Max. torque 1,143 {116}/1,450 {1,450}
{rpm}
Max. speed with no load
• When mounted on machine (*3) 2,050 {2,050}
min-1{rpm}
• At bear engine unit 2,050 {2,050}
Min. speed with no load min-1{rpm} 1,000 {1,000}
Min. fuel consumption ratio g/kWh {g/HPh} 205 {153}
Starting motor - 24 V、7.5 kW
Alternator - 24 V、60 A
Battery (*4) - 12 V, 140 Ah x 2
Radiator core type - Corrugated (aluminum), 4 rows
*3: When swing is locked.
*4: Battery capacity (Ah) is based on the 5-hour rate.
a The engine rated output is indicated in the net value and gross value. Gross denotes the rated output
measured of an independent engine. While, net denotes the value measured of an engine under the
condition essentially the same as that when it is installed on machine.
Undercarriage
Carrier roller - 2 (each side)
Track roller - 8 (each side)
Track shoe - Assembly type, triple grouser, 48 (each side)
01-6 PC360LC-10
01 Specification
Specifications

Unit
Hydraulic system
Hydraulic pump
Variable displacement piston type (HPV 140 +
Type x quantity -
140) x 2
Delivery l/min 267.5 × 2
Set pressure MPa {kg/cm2} 37.3 {380}
Control valve
Type x quantity - 6-spool and 1-spool type x 1
Operating method - Hydraulic
Travel motor
Variable displacement piston type
Type x quantity - (HMV180ADT-2) x 2
(with brake valve and shaft brake)
Swing motor
Fixed displacement piston type (KMF230ABE-
5) x 1
Type x quantity -
(with safety valve, shaft brake, reverse
prevention valve)
Boom cylinder (*5)
Type - Double-acting piston
Cylinder bore mm 140
Piston rod diameter mm 100
Stroke mm 1,480
Max. distance between pins mm 3,525
Min. distance between pins mm 2,045
Arm cylinder (*6)
Stroke mm 1,825
Bucket cylinder
Stroke mm 1,285
Hydraulic tank - Box-shaped sealed type
Hydraulic oil filter - Tank return side
Hydraulic oil cooler - Air cooled (CF40-1)
*5: With head side cushion.
*6: With head side cushion and bottom side cushion.
PC360LC-10 01-7
01 Specification
Weight table
Weight table (ALL-2120-001-A-01-A)
PC360LC-10 (PC300-2120-931-A-00-A)
k This weight table is prepared for your reference when handling or transporting the components.
Unit: kg
Engine assembly (excluding coolant and oil) 1,250
• Engine 1,030
• Damper 14.3
• Main pump 199
Cooling assembly (excluding hydraulic oil and coolant) 248
Hydraulic tank and filter assembly (hydraulic oil excluded) 190
Fuel tank assembly (fuel excluded) 250
Revolving frame 2,995
Operator's cab (head guard and front half guard included) 520
Operator seat 35
Counterweight 7,090
Swing machinery 442
Control valve 224
Swing motor 105
Travel motor 157×2
Center swivel joint 29.9
Track frame assembly (track shoe excluded) 8,287
• Track frame 4,424
• Swing circle 491
• Idler 169 × 2
• Idler cushion 297 × 2
• Carrier roller 28 × 4
• Track roller (double frame) 57.5×16
• Track roller (single frame) 52.2×16
• Final drive (travel motor and sprocket included) 603 × 2
Track shoe assembly
Wide triple grouser shoe (850 mm) 4,870
Boom 2,432
Arm 1,091
Bucket 1,508
01-8 PC360LC-10
01 Specification
Weight table
Unit: kg
Boom cylinder assembly 261×2
Arm cylinder assembly 388
Bucket cylinder assembly 234
Bucket link (large) assembly 316
Bucket link (small) assembly -
Boom foot pin 76
Boom cylinder bottom pin 15 × 2
Boom cylinder head pin 56
Arm cylinder bottom pin 13
Arm cylinder head pin 17
Boom and arm connecting pin 42
Bucket cylinder bottom pin 13
Bucket pin 30 × 2
Bucket link pin 27 × 2
PC360LC-10 01-9
01 Specification
Table of fuel, coolant and lubricants
Table of fuel, coolant and lubricants (PC300-RA19-05A-K-00-A)
a For details of the note (Note 1, Note 2... ) in the table, see the Operation and Maintenance Manual.
Unit: l
PC360LC-10
Reservoir
Specified capacity Refill capacity
Engine oil pan 35 35
Swing machinery case 16.5 13.7
Final drive case (each of right and
left) 9 9
Damper case 1.3 1.3
Hydraulic system 365 188
Cooling system 37 37
Fuel tank 605 -
01-10 PC360LC-10
SHOP MANUAL
HYDRAULIC EXCAVATOR
PC360LC-10
Model Serial Number
PC360LC-10 70001 and up
10 Structure and function

3 10 Structure and function
PC360LC-10 10-1
Table of contents

10 Structure and function ................................................................................................................... 10-1
Engine related parts ............................................................................................................. 10-3
KVGT.................................................................................................................................. 10-5
EGR system piping drawing ................................................................................................ 10-12
EGR system circuit diagram ................................................................................................ 10-14
EGR valve......................................................................................................................... 10-16
EGR cooler........................................................................................................................ 10-18
KCCV layout drawing ......................................................................................................... 10-19
KCCV ventilator ................................................................................................................. 10-22
KDPF................................................................................................................................ 10-24
Cooling system .................................................................................................................. 10-28
Power train............................................................................................................................... 10-30
Power train ........................................................................................................................ 10-30
Swing circle ....................................................................................................................... 10-31
Swing machinery ............................................................................................................... 10-32
Final drive ......................................................................................................................... 10-34
Hydraulic component layout ................................................................................................ 10-38
Valve control...................................................................................................................... 10-40
Hydraulic tank.................................................................................................................... 10-42
CLSS ................................................................................................................................ 10-44
Main pump ........................................................................................................................ 10-49
Control valve ..................................................................................................................... 10-74
Swing motor .................................................................................................................... 10-130
Travel motor .................................................................................................................... 10-141
PPC valve ....................................................................................................................... 10-156
Solenoid valve ................................................................................................................. 10-177
Attachment circuit selector valve ....................................................................................... 10-181
Center swivel joint ............................................................................................................ 10-184
Accumulator .................................................................................................................... 10-186
Work equipment ..................................................................................................................... 10-187
Work equipment............................................................................................................... 10-187
Cab mount and cab tipping stopper ................................................................................... 10-190
ROPS cab ....................................................................................................................... 10-191
Electrical control system ................................................................................................... 10-192
Machine monitor system ................................................................................................... 10-240
KOMTRAX system ........................................................................................................... 10-259
Sensor ............................................................................................................................ 10-262
10-2 PC360LC-10
Engine related parts
Engine and cooling system (ALL-R401-001-K-00-A)
Engine related parts (PC300-A001-041-K-00-A)
EGR cooler (*1)
PC360LC-10 10-3
Engine related parts
2. Engine oil filter

3. KDPF(*1)
4. KCCV ventilator (*1)
5. Vibration damper (*1)
6. Auto-tensioner
7. Air cleaner (*1)
8. KVGT(*1)
9. Damper assembly
9a. Drive plate
9b. Torsion spring
9c. Stopper pin
9d. Friction plate
10. Rear engine mount
11. Front engine mount
*1: For the details, see Engine Shop Manual.
Function (PC220-A001-042-K-00-A)
• KVGT (8) is a turbocharger which can vary the cross-sectional area in the exhaust circuit.
• EGR cooler (1) is a device which cools the exhaust gas with the coolant.
• KDPF (3) is a device which has KDOC (catalyzer) and KCSF (filter to catch soot) for purification of the
exhaust gas.
• KCCV (4) is a mechanism which mainly consists of filters and separates oil from blowby gas to return the
gas to the air intake side for afterburning.
Specifications (PC300-A001-030-K-00-A)
Damper type Wet type

Oil used for damper TO30
Damper oil quantity (l) 1.3
10-4 PC360LC-10
KVGT
KVGT (ENG114-AA10-041-K-00-A)
KVGT: Abbreviation for KOMATSU Variable Geometry Turbocharger and it is variable displacement
turbocharger.
a The shape is subject to machine models.
PC360LC-10 10-5
KVGT
1. Blower housing
2. KVGT speed sensor
3. Hydraulic actuator
4. Turbine housing
5. Plate
6. Vane
7. Nozzle ring
8. Push rod
9. Shaft
10. Blower impeller
11. Turbine impeller
12. Piston
A: Air intake inlet
B: Air intake outlet
C: Exhaust inlet
D: Exhaust outlet
Operation (ENG114-AA10-044-K-00-A)
1. Air cleaner
2. KVGT
3. KDPF
4. EGR cooler
5. EGR valve
C: Blower impeller
T: Turbine impeller
• The new exhaust gas regulation not only requires to control emissions at high engine speeds but also at
low engine speeds. To meet the requirements, the EGR ratio is increased. (EGR ratio = volume of EGR/
intake air flow)
• To obtain a high EGR ratio especially at low engine speeds, the turbine inlet pressure (P3) must be higher
than the boost pressure (P2). A variable displacement turbocharger (KVGT), in which the exhaust gas
pressure hitting the turbine impeller (T) can be adjusted, is introduced.
• The charged pressure rises faster, also contributing to suppress the generation of PM (particles) due to
insufficient oxygen at low engine speeds.
• The turbine impeller (T) drives the blower impeller (C) via a shaft. In turn the blower impeller (C) sends a
large amount of air to the cylinders for combustion. When the air flow from KVGT (2) increases, more fuel
can be injected, and the engine output increases.
• Since the density of the air and the amount of oxygen increases when the air is cooled, more fuel can be
injected, and the engine output increases.
10-6 PC360LC-10
KVGT
a Adequate amount of clean high quality oil is required to maintain the KVGT performance. Be sure to use
Komatsu genuine high quality oil. Follow the procedures in the Operation and Maintenance Manual when
replacing oil or oil filter.
• Exhaust gas enters from (C) of turbine housing (4), flows through section (P) and out from (D). Section (P)
is surrounded by plate (5) and nozzle ring (7) fixed on turbine housing (4), and vane (6).
• The passage area changes when push rod (8) slides right or left.
• The hydraulic actuator (3) moves piston (12) in the actuator up/down by using the oil pressure controlled
at the EPC valve installed to the EGR valve, and also controls the right/left slide of push rod (8).
• Exhaust gas hits vane (6), and then turbine impeller (11) drives blower impeller (10) via shaft (9). This
works as a compressor and the air entered from (A) is compressed and sent out from (B).
• When the exhaust gas pressure at the inlet (C) of turbine housing (4) is low (at low engine speeds), push
rod (8) slides to the right to narrow section (P).
• Then the exhaust gas pressure to turbine impeller (11) increases, the turbocharger speed also increases,
and more air (oxygen) is inhaled.
• The turbocharger speed is sensed by KVGT speed sensor (2).
When nozzle ring is closed

• At low engine speeds, exhaust gas inlet passage (P) is narrowed (L1). (Not completely closed)
• When the turbine inlet pressure increases while the nozzle ring is closed, the flow speed to the turbine
increases and the turbocharger speed increases.
PC360LC-10 10-7
KVGT
When nozzle ring is open

• At high engine speeds, exhaust gas inlet passage (P) is widened (L2).
• As the engine speed and the turbine inlet pressure (exhaust gas pressure) increases, exhaust gas inlet
passage (P) widens (L2) to effectively apply the exhaust gas pressure to turbine impeller (11).
a Nozzle ring (7), vane (6), and push rod (8) are integrated and slide together but do not rotate.
a KVGT position sensor is installed to hydraulic actuator (3). The KVGT position sensor is calibrated
together with the variable mechanism in the KVGT, and values are stored in the memory inside the KVGT
position sensor. If any of the hydraulic actuator (3), KVGT position sensor, or KVGT body fails, replace the
whole KVGT.
Hydraulic actuator operation
• Hydraulic actuator (6) is moved by the oil pressure controlled by EPC valve (8) installed to EGR valve
(10).
• The force for the movement is the oil pressure supplied from boost oil pump (12).
a The D65EX–17 is shown as an example. The shape is subject to machine models.
10-8 PC360LC-10
KVGT
• Position of hydraulic actuator (6) is sensed by KVGT position sensor (5) and the signals are fed back to
engine controller (7).
PC360LC-10 10-9
KVGT
1. Air cleaner
2. Mass air flow and temperature sensor
3. KVGT
4. KVGT speed sensor
5. KVGT position sensor
6. Hydraulic actuator
7. Engine controller
8. EPC valve (for KVGT)
9. KDPF
10. EGR system (EGR cooler, EGR valve)
11. EGR orifice temperature sensor
C: Blower impeller
T: Turbine impeller
KVGT control system

• Based on information from KVGT position sensor (5), mass air flow and temperature sensor (2), and
KVGT speed sensor (4), etc., the engine controller (7) moves hydraulic actuator (6) by using the oil
pressure controlled by EPC valve (8), to move the piston.
• A good response at high altitudes is maintained by sensing high elevations with the ambient pressure
sensor, and automatically controlling the fuel injection and the KVGT.
• The KVGT is protected by controlling its speed to prevent overspeeds.
Lubrication
• Cooled oil from the engine oil cooler is sent through the supply pipe to the KVGT for lubrication.
• Oil is sent to the bearing housing to lubricate the shaft bearing and thrust bearing.
• Return oil is drained from the return pipe connected to the bottom of the bearing housing and falls to the oil
pan.
10-10 PC360LC-10
KVGT
Cooling
• Coolant from the cylinder block enters the center housing to cool the KVGT.
• Coolant return flows from the center housing and joins the flow at the EGR cooler outlet piping, then flows
through the water inlet connector to the water pump.
PC360LC-10 10-11
EGR system piping drawing
EGR system piping drawing (ENG114-A9J0-04D-K-00-A)
EGR: Abbreviation for Exhaust Gas Recirculation.

a The D65EX-17 is shown as an example. The shape is subject to machine models.
1. KVGT
2. EGR valve
3. Air intake pipe
4. Air intake connector
5. Exhaust manifold
6. EGR cooler
Function (ENG107-A9J0-042-K-00-A)
• EGR valve (driven hydraulically)

Controls the gas flow from the exhaust system to the air intake system. Since the exhaust pressure is
higher than the boost pressure, the exhaust gas flows to the air intake side.
• EGR cooler
Cools the exhaust gas.
Engine coolant is used for cooling.
• Air intake connector
Returns the air from the air-cooled aftercooler and exhaust gas from the EGR valve to the air intake side.
• Each sensor
Controls the EGR according to the operating condition.
Troubleshoots the system.
10-12 PC360LC-10
EGR system piping drawing
• Controls each part of the EGR circuit and controls the EGR rate according to the operating condition to
ensure clean exhaust at all times.
• Since the EGR circuit is monitored and troubleshooted, a serious trouble is prevented.
PC360LC-10 10-13
EGR system circuit diagram
EGR system circuit diagram (ENG107-A9J0-052-K-00-A)
a EGR: Abbreviation for Exhaust Gas Recirculation
1. Air cleaner
2. KDPF
3. Ambient pressure sensor
4. Aftercooler
5. EGR orifice temperature sensor
6. EGR cooler
7. EGR valve
8. Hydraulic actuator (power piston)
9. EPC valve (for EGR valve)
10. EGR valve lift sensor
12. Exhaust manifold
13. Boost oil pump
14. Air intake manifold
15. Charge (boost) pressure and temperature sensor
C: Blower impeller
T: Turbine impeller
Operation (ENG107-A9J0-044-K-00-A)
• The engine controller outputs signals for opening EGR valve (7) most properly according to the load on
the engine to attain both clean exhaust gas and low fuel consumption.
• When EGR valve (7) opens, a part of the exhaust gas (EGR gas) flows from exhaust manifold (12)
through EGR piping to EGR cooler (6).
10-14 PC360LC-10
EGR system circuit diagram
• The exhaust gas cooled by EGR cooler (6) flows through EGR valve (7) and mixes with the intake air in
the air intake connector, and then flows in the air intake manifold (14).
PC360LC-10 10-15
EGR valve
EGR valve (ENG107-A9K1-041-K-00-A)
1. Valve
2. Spring
3. Power piston
4. Spool
5. Spring
6. EGR valve lift sensor
7. EPC valve (for EGR valve)
A: EGR gas inlet (from EGR cooler)
B: EGR gas outlet (to intake manifold)
C: Servo drive oil inlet
D: Servo drive oil outlet
E: KVGT control oil pressure outlet
F: KVGT drive oil pressure outlet
Structure
• The EGR valve consists of the EGR gas flow control mechanism and the EPC valves
• There are two EPC valves, one for the EGR valves control and one for the KVGTcontrol.
10-16 PC360LC-10
EGR valve
Operation (ENG107-A9K1-044-K-00-A)
• Oil from the boost oil pump flows into the EGR valve from port (C). Control pressure from the EPC valve
flows into port (E).
• Spool (4) is pressed to the right by the reaction force of spring (5), and EGR valve (1) is closed by the
reaction force of spring (2) Therefore, exhaust gas from the EGR cooler does not flow to the intake side.
• To open EGR valve (1), first the control pressure from the EPC valve enters port (E). Spool (4) moves to a
position whereat this control pressure and the force of spring (5) are balanced.
• The hydraulic circuit in power piston (3) opens, and then the oil from the boost oil pump entering from port
(C) pushes power piston (3) to the left.
• Oil from the boost oil pump acts on power piston (3) and generates force (Fp).
• When force (Fp) becomes larger than reaction force (Fs) of spring (2), EGR valve (1) opens and then
exhaust gas will flow to the intake side.
• Since the hydraulic circuit to spool (4) is closed by movement of power piston (3), power piston (3) stops at
a position determined by spool (4).
• The valve position is controlled by the engine controller by controlling the spool position with the control
pressure of the EPC valve.
• A servo mechanism prevents external force applied to valve (1) from acting on spool (4), which is in
contact with power piston (3).
• Position of spool (4) is sensed by the EGR valve lift sensor.
PC360LC-10 10-17
EGR cooler
EGR cooler (ENG107-A9L0-041-K-00-A)
1. Tube
A: EGR gas inlet
B: Air vent
C: Coolant outlet
D: EGR gas outlet (to EGR valve)
E: Coolant inlet
1. Flat tube
2. Inner fin
Operation (ENG107-A9L0-044-K-00-A)
• The EGR gas enters from (A) and flows through 11 flat tubes (1).
• Coolant enters from (E) and flows around flat tube (1) in shell and then goes out from (C).
• The EGR gas is effectively cooled by flat tubes (1) with inner fins (2) and flows out from EGR gas outlet
(D).
10-18 PC360LC-10
KCCV layout drawing
KCCV layout drawing (ENG114-A180-04D-K-00-A)
KCCV: Abbreviation for KOMATSU Closed Crankcase Ventilation

a The D65EX-17 is shown as an example. The shape is subject to machine models.
1. KCCV ventilator
PC360LC-10 10-19
KCCV layout drawing
2. KVGT
3. Breather
4. Flywheel housing
5. Check valve
6. CDR valve
7. Crankcase pressure sensor
A: Blowby gas (from flywheel housing)
B: Engine oil-free blowby gas (to KVGT)
C: Engine oil (to oil pan)
• Formerly, blowby gas (A) has been released to the atmosphere. However, since the tightened exhaust gas
regulation also regulates blowby gas, the blowby gas recirculation system is adopted.
• Since blowby gas (A) contains engine oil mist, which may cause the following problems when recirculated
to KVGT (2), a filter is provided at KCCV ventilator (1) to remove the oil.
1. Degraded performance of turbocharger and aftercooler due to adherence of engine oil
2. Abnormal engine combustion
3. Malfunction of sensors due to aherence of engine oil
Operation (ENG107-A180-044-K-00-A)
a The figure on the left shows the flow of blowby gas released to the atmosphere from conventional engines.
The figure on the right shows the flow of blowby gas recirculated to the intake system by the KCCV
ventilator.
1. Air cleaner
2. KVGT
3. Aftercooler
4. Cylinder block (crankcase)
5. Breather
6. KCCV ventilator
10-20 PC360LC-10
KCCV layout drawing
7. Oil pan
• Engine oil mist is removed from blowby gas (A) in cylinder block (4) by the filter in KCCV ventilator (6), and
then the cleaned gas (B) is recirculated to the intake side of the KVGT.
• Removed engine oil (C) flows through a check valve and falls to the oil pan.
PC360LC-10 10-21
KCCV ventilator
KCCV ventilator (ENG114-A18H-041-K-00-A)
1. Case
2. CDR valve
3. Crankcase pressure sensor
4. Relief valve
5. Impactor
6. Filter
A: Blowby gas inlet (from breather)
B: Blowby gas outlet (to KVGT intake side)
C: Oil drain port (to oil pan)
Function (ENG107-A18H-042-K-00-A)
• When blowby gas is recirculated to the intake side of the KVGT, the pressure inside the crankcase
becomes negative, and dust may be sucked in through the crankshaft seals. Therefore, CDR valve
(regulator valve) controls the pressure inside the crankcase.
• If the filter in the KCCV ventilator clogs, pressure inside the crankcase increases and oil may leak, so clog
of filter is detected by crankcase pressure sensor.
• There are two types of filters that differ by the filter replacement method; the top load type (removed
upward) and the bottom load type (removed downward).
Operation (ENG107-A18H-044-K-00-A)
• Blowby gas enters (A) and large oil particles in the engine oil mist are separated when it flows through the
hole of impactor (5) in filter (6).
• Small oil particles are separated by filter (6).
• The separated oil flows along the case wall to oil drain port (C), and then flows into the oil pan.
• When the crankcase pressure becomes negative, CDR valve (2) operates to prevent the crankcase
pressure from becoming excessively negative.
• The crankcase pressure sensor (3) senses the blowby gas pressure (crankcase pressure).
10-22 PC360LC-10
KCCV ventilator
• If the engine controller judges from the value sensed by the crankcase pressure sensor (3) that the filter is
clogged, it displays failure code CA555 and then displays CA556 if the pressure increases further.
• Relief valve (4) is installed inside case (1) and operates to protect the KCCV ventilator and engine when
filter (6) is blocked.
CDR valve (ENG107-A18A-041-K-00-A)
CDR: Abbreviation for Crankcase Depression Regulator
1. Diaphragm
2. Spring
A: Crankcase side
B: KVGT side (intake side)
• The CDR valve is a regulator valve which prevents excessive negative crankcase pressure (P1).
• Normally, diaphragm (1) is pushed up by spring (2) and blowby gas flows from crankcase side (A) to
KVGT side (intake side) (B).
• When intake air flow at KVGT side (intake side) (B) increases and crankcase pressure (P1) decreases, the
reaction force of spring (2) yields to ambient pressure (P2). The diaphragm shuts the passage and
temporarily blocks the flow.
• Then, when blowby gas accumulates in the crankcase and pressure (P1) recovers, the diaphragm is
pushed up again and blowby gas starts to flow again.
PC360LC-10 10-23
KDPF
KDPF (ENG114-A9H0-041-K-00-A)
KDPF: Abbreviation for KOMATSU Diesel Particulate Filter

1. Inlet unit
2. KDOC inlet temperature sensor
3. KDOC outlet temperature sensor
4. KCSF unit
5. Connector box
6. KDPF outlet temperature sensor
7. Outlet unit
8. KDPF differential pressure sensor port
9. KDPF differential pressure sensor
10. KDPF differential pressure sensor port
11. KDOC unit
12. Hanger bracket
13. Sensor bracket
14. Sensor bracket band
15. Water drain port
A: From KVGT
B: Exhaust
C: Water drain
• The KDPF consists of the following components: inlet unit (1) to introduce exhaust gas, KDOC unit (11)
that houses an oxidation catalyst, KCSF unit (4) that houses a soot collecting filter with a catalyzer, and
outlet unit (7) that sends out exhaust gas and has a "dam" to prevent rain water from entering KCSF unit
(4).
• KDOC unit (11) consists of a ceramic honeycomb coated with oxidation calatyst material.
10-24 PC360LC-10
KDPF
• The ceramic honeycomb supports the oxidization of NO (nitrogen monoxide) into NO 2 (nitrogen dioxide),
and also contributes to burn the injected fuel during automatic regeneration (*1) and manual stationary
regeneration.
• The ceramic honeycomb is guarded by a mat made of special fiber to prevent damage caused by engine
and machine vibrations.
• The mat also prevents overheating of the KDPF outer periphery by insulating the heat generated at the
ceramic honeycomb during operation.
• KCSF unit (4) also consists of a ceramic honeycomb coated with oxidation catalyst material, like the
KDOC unit (11). This ceramic honeycomb collects soot.
• Inside the KCSF, there are many cells partitioned by ceramic walls. Cells plugged at the inlet side and
cells plugged at the outlet side are alternately arranged.
• Three temperature sensors and one differential pressure sensor (an integrated KDPF differential pressure
and KDPF outlet pressure sensor) are installed to the KDPF.
• Temperature signals from the three temperature sensors are used in combination to monitor the KDOC
and KCSF operations and to perform various troubleshootings.
• The differential pressure sensor detects the amount of soot deposited in the KCSF by sensing the
pressure difference across the KCSF. Like the temperature sensors, this sensor is also used for various
troubleshootings.
*1: Soot is cleaned (oxidized) during the process.
k During engine operation and for a while after engine shutdown, the surface of the KDPF and
adjacent pipings are very hot. When working near the KDPF, be careful not to get burned.
Function (ENG107-A9H0-042-K-00-A)
A: Flow of exhaust gas

1 KDOC (oxidation catalyzer)
2 KCSF
3 Sealing (ceramic)
4 Cell
5 Ceramic honeycomb
PC360LC-10 10-25
KDPF
• KDPF is installed to meet the latest very severe emission regulations. It captures almost all PM
(Particulate Matter) contained in the engine exhaust gas to clean the exhaust gas.
• KCSF (2) is made of ceramic. Inside KCSF, there are many cells partitioned by ceramic walls. Cells
plugged at the inlet side and cells plugged at the outlet side are alternately arranged.
• The soot deposited in KCSF (2) are naturally oxidized and burned away by the effect of KDOC (1), in
operating conditions with relatively high exhaust gas temperatures. (This is referred to as "passive
regeneration".)
• On the other hand, when the exhaust temperature is relatively low, in conditions such as continued low
load operations, the deposit of soot in KCSF (2) increases.
• The engine controller continuously monitors the amount of deposited soot by estimating from the
operating conditions and calculating from the signals of the differential pressure sensor installed to KCSF
(2).
• When the soot deposit exceeds a certain level, and the engine is operated with the exhaust gas
temperature exceeding a certain level, the engine controller executes "automatic regeneration" to burn
(oxidize) the soot.
• During automatic regeneration, the engine controller automatically controls the fuel injection timing and
the KVGT to raise the exhaust temperature. This operation is called "exhaust temperature-raising control".
• As the exhaust temperature increases, the engine controller automatically performs calculations based on
the exhaust temperature at KDOC (1) inlet and flow of the exhaust gas, so that KCSF (2) can efficiently
burn (oxidize) the soot.
• KDOC (1) burns (oxidizes) the soot by utilizing the function of the catalyzer.
• Automatic regeneration is not performed when regeneration is executed from the machine monitor, or
when the outside air temperature is extremely low, and when the exhaust gas temperature is not high
enough to burn soot because the engine has been operated at low loads for a while. Thus, soot deposit in
the KCSF (2) will increase.
• If the soot deposit in the KCSF (2) exceeds a certain level, it will be necessary to perform "manual
stationary regeneration" to burn away (oxidize) the soot in the KCSF (2).
• If the soot deposit exceeds the acceptable level, the exhaust gas flow will be restricted. This can increase
fuel consumption, degrade engine combustion, or cause other problems.
• If the soot deposit exceeds the limit to safely perform "manual stationary regeneration", the KDPF fails and
replacement becomes unavoidable. Make sure to follow the procedures in the Operation and
Maintenance Manual when performing "manual stationary regeneration"
Types of regeneration (ENG107-A9H0-042-K-01-A)
a Regeneration refers to a process of purifying (oxidizing) the soot deposited in the soot collecting filter
(KCSF) inside the KDPF.
1. Passive regeneration
When the exhaust temperature is relatively high, the catalyst effect of the KDOC to oxidize soot will be
stronger and the soot deposit in the KCSF will be naturally burned away.
2. Active regeneration
1) Automatic regeneration
If the soot deposit exceeds a certain level, the engine controller switches to exhaust temperature-
raising control (*1), performs fuel dosing (*2), and automatically starts the regeneration process.
Another type of automatic regeneration is performed by the engine controller at certain intervals,
regardless of the amount of soot deposited in the KCSF.
*1: The fuel injection timing and the KVGT are controlled to raise the exhaust temperature.
*2: Fuel is injected to increase the exhaust temperature and accelerate the regeneration process. No.
1, 2, and 3 injectors are used for fuel dosing.
2) Manual stationary regeneration (*3)
When the exhaust temperature does not reach a certain level due to the machine operating condition,
or when regeneration is disabled by the operator, automatic regeneration will not be performed and the
soot deposit in the KCSF may increase. In such conditions, the machine monitor displays a manual
stationary regeneration request on the screen. The operator must perform regeneration by operating
the machine monitor on its screen. A regeneration feature is also provided for the technician who
should use this feature from the machine monitor menu after engine controller replacement, KDPF
replacement, and KCSF ash cleaning. (= Regeneration for service (*3))
*3:For details, see the Shop Manual for the applicable machine.
10-26 PC360LC-10
KDPF
• A KDPF drying feature is provided to prevent excessive accumulation of unburned fuel in the KDPF
when the machine is operated for a long time with low exhaust temperature.
• When certain conditions are met, the engine controller automatically switches control to increase
the exhaust temperature to dry the KCSF. If some of the conditions for automatic drying are not met,
manual stationary regeneration may be requested.
a Follow the procedures in the Operation and Maintenance Manual when starting and stopping
KDPF regeneration.
a Be sure to use ultra-low-sulfur diesel fuel. Non-specified fuels may cause KDPF failure.
a Be sure to use the specified Komatsu genuine oil for the KDPF. Non-specified oils may cause
KDPF clogging in a short time, resulting in increased fuel consumption or KDPF failure.
a Do not modify the KDPF itself or exhaust pipes. Modifications disturb normal operation of the
KDPF, leading to a failure.
a Do not apply impacts to the KDPF by stepping on, dropping, or striking it. The KDPF contains a
ceramic honeycomb, which can be damaged by strong impacts.
a The engine controller performs automatic regeneration even when the amount of soot deposit is
low. Since this is programmed to maintain the KDPF performance, this is normal.
a During automatic regeneration and manual stationary regeneration, the KVGT automatically
operates and the engine sound changes. The flow of exhaust gas through the KDPF changes
and the exhaust sound changes, but this is normal.
a During automatic regeneration and manual stationary regeneration, especially at low
temperatures, white smoke may come out from the exhaust pipe for a short time, but this is
normal. Be sure to perform regeneration at a well ventilated place since carbon monoxide can
be produced.
a During automatic regeneration and manual stationary regeneration, a strange odor may be
smelled from the exhaust pipe, but this is normal.
a During automatic regeneration and manual stationary regeneration, the exhaust temperature at
the exhaust pipe can exceed 650 °C. Make sure that there is no flammable material near the
exhaust system to prevent fire. Make sure that nobody is standing in front of the exhaust pipe,
and pay sufficient attention to safety of the environment.
a KDPF temperature values are shown below for reference.
DOC_In (KDOC inlet DOC_Out (KDOC outlet KDPF_Out (KDPF outlet
temperature sensor) temperature sensor) temperature sensor)
Not regenerating (idling) 100 to 250 °C
Regenerating (under
exhaust temperature-raising 100 to 250 °C 400 to 550 °C
control: 1,000 rpm)
PC360LC-10 10-27
Cooling system
Cooling system (PC300-B000-041-K-00-A)
1. Reservoir tank
2. Radiator
3. Radiator cap
4. Oil cooler
5. Fan guard
6. Aftercooler
7. Radiator inlet hose
8. Radiator outlet hose
9. Shroud
10-28 PC360LC-10
Cooling system
Specifications (PC300-B000-030-K-00-A)
Radiator Oil cooler Aftercooler

4-array aluminum
Core type CF40-1 Corrugated aluminum
corrugated core
Fin pitch (mm) 3.5/2 3.5/2 4.0/2
Total heat dissipation area
(m2) 76.39 12.31 x 3 17.55
Pressure valve cracking
0.05 {0.5} – –
pressure (MPa {kg/cm2})
Vacuum valve cracking
-0.005 {-0.05} – –
pressure (MPa {kg/cm2})
PC360LC-10 10-29
Power train
Power train (ALL-C100-001-K-00-A)
Power train (PC300-C100-041-K-00-A)
1. Idler
2. Center swivel joint
3. Control valve
4. Final drive
5. Travel motor (HMV180ADT-2)
6. Engine (SAA6D114E)
7. Main pump (HPV140 + 140)
8. Travel speed solenoid valve
9. Swing brake solenoid valve
10. Swing machinery
11. Swing motor (KMF230ABE-5)
12. Swing circle
10-30 PC360LC-10
Swing circle
Swing circle (PC300_10-J110-041-K-00-A)
1. Swing circle pinion greasing port

2. Inner race (Number of teeth: 90)
3. Ball
4. Outer race
5. Seal
a. Inner race soft zone "S" position
b. Outer race soft zone "S" position
Specifications (PC300_10-J110-030-K-00-A)
Reduction ratio -90/13 = -6.923

Grease G2-LI
Grease quantity (l) 33
PC360LC-10 10-31
Swing machinery
Swing machinery (PC300_10-J130-041-K-00-A)
1. Swing pinion (number of teeth: 13)

2. Cover
3. Plate
10-32 PC360LC-10
Swing machinery
4. No.2 planetary carrier

5. Ring gear
6. No.2 planetary gear (Number of teeth: 25)
7. No.2 sun gear
9. No.1 planetary gear (Number of teeth: 24)
10. Swing motor
11. Oil level gauge
12. No.1 sun gear
13. Case
14. Drain plug
Specifications (PC300_10-J130-030-K-00-A)
Reduction ratio ((19 + 68)/19) x ((24 + 68)/24) = 17.553

Swing gear reduction ratio 17.553 x 90/13 = 121.518
PC360LC-10 10-33
Final drive
Final drive (PC300-DF10-041-K-00-A)
1. Level plug
2. Drain plug
3. No. 1 planetary gear (number of teeth: 42)
4. No. 1 sun gear (number of teeth: 10)
5. No. 2 sun gear (number of teeth: 19)
7. No. 2 planetary carrier
8. Cover
9. Ring gear (number of teeth: 95)
10. Hub
11. Sprocket
12. Floating seal
13. Travel motor
10-34 PC360LC-10
Final drive
14. No. 2 planetary gear (number of teeth: 37)

Specifications (PC300-DF10-030-K-00-A)
Reduction ratio -((10 + 95)/10) x ((19 + 95)/19) + 1 = -62.000
PC360LC-10 10-35
Track frame and idler cushion
Undercarriage and frame (ALL-DT00-001-K-00-A)
Track frame and idler cushion (PC300-DT20-041-K-01-A)
1. Idler
2. Track frame
3. Carrier roller
4. Final drive
5. Track roller
6. Center guard
7. Idler cushion
8. Front guard
9. Track shoe
10-36 PC360LC-10
Specifications (PC300-DT20-030-K-00-A)
• Number of track rollers

Model Quantity (each side)
PC360LC-10 8
• Standard shoe
Model PC360LC-10
Shoe width (mm) 850
Link pitch (mm) 216
Number of shoes (each side) 48
PC360LC-10 10-37
Hydraulic component layout
Hydraulic system (ALL-C000-001-K-00-A)
Hydraulic component layout (PC300-C000-04D-K-00-A)
1. Bucket cylinder
10-38 PC360LC-10
Hydraulic component layout
2. Arm cylinder
3. Boom cylinder
4. Swing motor
5. Control valve
6. Oil cooler
7. Hydraulic oil filter
8. Main pump
9. L.H. travel motor
10. Hydraulic tank
11. Multi-pattern selector valve
12. L.H. PPC valve for work equipment
13. Lock lever (electric type)
14. Center swivel joint
15. R.H. PPC valve for work equipment
16. Travel PPC valve
17. Attachment hydraulic circuit selector valve
18. Anti-drop valve
19. Accumulator
20. Solenoid valve assembly
20A. PPC lock solenoid
20B. Swing motor 2-stage relief solenoid
20C. Travel interconnection solenoid
20D. Travel speed solenoid
20E. Swing holding brake solenoid
20F. Machine push-up solenoid
20G. 2-stage relief solenoid
PC360LC-10 10-39
Valve control
Valve control (PC300-PK01-041-K-00-A)
1. Travel PPC valve

2. Single line attachment PPC valve (*1)
3. Single line attachment control pedal (*1)
4. L.H. travel lever
5. R.H. travel lever
6. R.H. PPC valve
7. R.H. work equipment control lever
8. Solenoid block
9. Accumulator
10. Control valve
11. Main pump
12. Relay block
13. L.H. work equipment control lever
10-40 PC360LC-10
Valve control
14. L.H. PPC valve

15. Attachment 2 PPC valve (*1)
16. Attachment 2 control pedal (*1)
*1: Machine ready for installation of attachment
PC360LC-10 10-41
Hydraulic tank
Hydraulic tank (PC300-PM30-041-K-00-A)
1. Filler cap
2. Bypass valve
3. Strainer
4. Filter element
5. Sight gauge
6. Hydraulic tank
7. Additional breather
10-42 PC360LC-10
Hydraulic tank
Specifications (PC300-PM30-030-K-00-A)
Hydraulic tank capacity (l) 275

Amount of oil in hydraulic tank (l) 188
Pressure valve (*1)
16.7 ± 6.9 {0.17 ± 0.07}
Set pressure at relief (kPa {kg/cm2})
Pressure valve (*1)
0 to 0.49 {0 to 0.005}
Set pressure at suction (kPa {kg/cm2})
Bypass valve set pressure (kPa {kg/cm2}) 150 ± 30 {1.5 ± 0.3}
Set pressure at additional breather relief (kPa {kg/cm2}) 100 ± 15 {1.0 ± 0.15}
Set pressure at additional breather suction (kPa {kg/cm2}) 2 ± 0.3 {0.02 ± 0.003}
*1: This valve is equipped inside the oil filler cap.
Oil filler cap (PC300-AD1C-041-K-00-A)
Oil filler cap
1. Filter element
2. Bottom plate
3. Gasket
4. Seam valve
5. Spring
Prevention of negative pressure in tank

• The hydraulic tank is sealed and pressurized. When the oil level in the hydraulic tank drops, negative
pressure is generated in the tank. To prevent this negative pressure generation, seam valve (4) opens to
draw the atmosphere to the tank.
(Set pressure at suction: 0 to 0.49 kPa {0 to 0.005 kg/cm2})
Prevention of pressure rise in tank

• When the hydraulic circuit is working, the pressure in the hydraulic tank increases as the hydraulic
cylinders operate, and the oil level and temperature increase in the tank. If the pressure in the tank rises
above the set value, bottom plate (2) is pushed up to release the pressure in the tank.
(Valve set pressure at relief: 16.7 ± 6.9 kPa {0.17 ± 0.07 kg/cm 2})
PC360LC-10 10-43
CLSS
CLSS (ALL-PNJ1-001-K-00-A)
a CLSS: Abbreviation for Closed center Load Sensing System

Structure of CLSS (ALL-PNJ1-041-K-00-A)
CLSS: Abbreviation for Closed center Load Sensing System
Features
• Fine control not influenced by load
• Control performance that allows digging even when fine control operation is turned on
• Ease of combined operation enabled by the flow divider function that is determined by the opening areas
of spools during combined operations
• Energy saving by variable pump control
Configuration
• CLSS consists of variable capacity piston pump, control valve, and actuators.
• The main pump consists of pump itself, PC valve and LS valve.
10-44 PC360LC-10
CLSS
Basic principle
Pump swash plate angle control

• The pump swash plate angle (pump delivery) is controlled so that LS differential pressure (dPLS), which is
the difference between pump delivery pressure (PP) and LS pressure (PLS)) (load pressure of actuator) at
control valve outlet, is constant.
• [LS differential pressure (dPLS) = Pump delivery pressure (PP) - LS pressure (PLS)]
• The pump swash plate angle shifts toward the maximum position if LS differential pressure (dPLS) is
lower than the set pressure of the LS valve (when the actuator load pressure is high).
• If it becomes higher than the set pressure (when the actuator load pressure is low), the pump swash plate
angle shifts toward the minimum position.
PC360LC-10 10-45
CLSS
LS differential pressure (d
d PLS) and pump swash plate angle
a See "Main pump" for the explanation of the operation.
Pressure compensation control
10-46 PC360LC-10
CLSS
• A pressure compensation valve is installed to the outlet port side of each control valve to balance the load
pressure.
• When actuators are operated in combination, the pressure difference (dP) between the upstream (inlet
port) and downstream (outlet port) of the spool of each valve becomes the same regardless the size of the
load (pressure).
• The flow of oil from the pump is divided (compensated) in proportion to the areas of openings (S1) and
(S2) of each valve.
System diagram
a The illustration shows the state when actuator (7) is relieved at the stroke end in the merge mode.
1. Front pump
2. Rear pump
3. Main relief valve
4. Unload valve
5. Merge-divider valve
6. Control valve
PC360LC-10 10-47
CLSS
7. Actuator
8. Pump circuit
9. LS circuit
10. Tank circuit
11. Valve
12. Spring
13. LS bypass plug
14. LS valve
15. PC valve
10-48 PC360LC-10
Main pump
Main pump (PC300-C200-041-K-00-A)
Model: HPV140 + 140
BMP: Breather mounting port

IMF: Front pump PC mode selector current
PC360LC-10 10-49
Main pump
IMR: Rear pump PC mode selector current

ISIG: LS set pressure selector current
OCP: Oil level pick-up port
PAF: Front pump discharge port
PAR: Rear pump discharge port
PBF: Front pump pressure input port
PBR: Rear pump pressure input port
PD1F: Air bleeder
PD1R: Case drain port
PD2F: Drain plug
PD2R: Drain plug
PENF: Front pump control pressure pickup port
PENR: Rear pump control pressure pickup port
PEPC: EPC source pressure input port
PEPB: EPC source pressure pickup port
PFC: Front pump delivery pressure pickup port
PSIG: LS set selector pressure pickup port
PLSF: Front pump load pressure input port
PLSFC: Front pump load pressure pickup port
PLSR: Rear pump load pressure input port
PLSRC: Rear pump load pressure pickup port
PMF: Front pump PC mode selector pressure pickup port
PMR: Rear pump PC mode selector pressure pickup port
PRC: Rear pump delivery pressure pickup port
PS: Pump suction port
1. Front pump
2. Rear pump
3. LS valve
4. PC valve
5. LS-EPC valve
6. Front pump PC-EPC valve
7. Rear pump PC-EPC valve
10-50 PC360LC-10
Main pump
1. Front shaft
2. Cradle
3. Front case
4. Rocker cam
5. Shoe
6. Piston
7. Cylinder block
8. Valve plate
9. End cap
10. Rear shaft
11. Rear case
12. PC valve
13. Servo piston
14. Slider
PC360LC-10 10-51
Main pump
15. Spline
16. Bearing
Outline
• This pump consists of two variable capacity swash plate piston pumps, PC valve, LS valve, EPC valve,
and swash plate sensor.
Function
• The pump converts the engine torque transmitted to its shaft (1) into oil pressure and delivers the
pressurized oil corresponding to the load.
• It is possible to change the delivery by changing the swash plate angle.
Structure
• Cylinder block (7) is supported to shaft (1) by spline (15).
• Shaft (1) is supported by each bearing (16) at the front and rear.
• The tip of piston (6) is shaped as a concave sphere and is crimped together with shoe (5).
• Piston (6) and shoe (5) form a spherical bearing.
• Rocker cam (4) has flat surface (A), and shoe (5) is always pressed against this surface while sliding in a
circular pattern.
• Rocker cam (4) conducts high pressure oil to cylinder surface (B) contacted with cradle (2), which is
secured to the case, and forms a static pressure bearing when it slides.
• Piston (6) performs the reciprocation axially inside each cylinder chamber of cylinder block (7).
• Cylinder block (7) seals the pressurized oil to valve plate (8) and performs relative rotation.
• This surface is designed so that the oil pressure balance is maintained at a suitable level.
• The oil is sucked into and discharged from each cylinder in cylinder block (7) through valve plate (8).
Operation (PC300-C200-044-K-00-A)
• Cylinder block (7) rotates together with shaft (1) and shoe (5) slides on plane (A).
• Rocker cam (4) moves along cylindrical surface (B). As a result, angle (a) between center line (X) of
rocker cam (4) and the axis of cylinder block (7) changes.
• Angle (a) is called the swash plate angle.
• If swash plate angle (a) is made between center line (X) of rocker cam (4) and the axis of cylinder block (7),
plane (A) functions as a cam against shoe (5).
• If angle (a) is made between center line (X) of rocker cam (4) and the axis of cylinder block (7), plane (A)
works as a cam for shoe (5).
• Oil in amount of (F) minus (E) goes in and out of each cylinder.
• Oil is discharged while cylinder block (7) rotates and the volume of chamber (E) decreases.
• Oil is sucked in when the volume of chamber (7) increases.
10-52 PC360LC-10
Main pump
• As center line (X) of rocker cam (4) matches the axis of cylinder block (7) (swash plate angle = 0), the
difference between volumes (E) and (F) inside cylinder block (7) equals 0.
• The hydraulic oil is not sucked or discharged. (Actually, however, the swash plate angle does not become
to 0)
Control of delivery
• If swash plate angle (a) increases, the difference between volumes (E) and (F) increases, and pump
delivery (Q) increases.
• Swash plate angle (a) is changed by servo piston (13).
• Servo piston (13) moves in a linear reciprocating movement according to the signal pressure from the PC
valve and LS valve.
• This linear reciprocating movement is transmitted to rocker cam (4) through slider (14).
• Being supported by cradle (2) on the cylindrical surface, rocker cam (4) slides on the surface while
continuing revolving movement.
• Output pressure (PEN) of LS valve is supplied to the chamber receiving the pressure at the large diameter
piston end.
• The areas receiving the pressure on the right and left sides of servo piston (13) are different from each
other, and delivery pressure (self pressure) (PP) of the main pump is constantly transmitted to the
pressure chamber of the small diameter piston side.
• The movement of servo piston (13) is controlled by the relationship of pressure between small diameter
piston side (PP) and large diameter piston side (PEN) and by the ratio of the areas receiving the pressure
of the small diameter piston and large diameter piston.
PC360LC-10 10-53
Main pump
10-54 PC360LC-10
Main pump
LS valve (PC300-C2J0-041-K-00-A)
LS: Abbreviation for Load Sensing
PA: Pump port

PDP: Drain port
PLP: LS control pressure output port
PLS: LS pressure input port
PP: Pump port
PPL: Control pressure input port
PSIG: LS mode selector pilot port
1. Sleeve
2. Piston
3. Spool
4. Spring
5. Seat
6. Sleeve
7. Plug
8. Locknut
Function (PC300-C2J0-042-K-00-A)
• The LS (load sensing) valve detects the load of the actuator and controls the discharge amount.
• This valve controls pump delivery (Q) with the differential pressure (dPLS) [= (PP) - (PLS)] (called the LS
differential pressure) between pump delivery pressure (PP) and control valve outlet pressure (PLS).
• This valve receives main pump delivery pressure (PP), pressure (PLS) (called the LS pressure) coming
from the control valve output, and pressure (PSIG) (called the LS set selector pressure) from the
proportional solenoid valve.
• The relation between the pump delivery (Q) and the differential pressure (dPLS) [= (PP) - (PLS)] between
the main pump pressure (PP) and LS pressure (PLS) is changed by the LS set pressure selector current
(ISIG) of the LS-EPC valve as shown in the figure below.
• If (ISIG) changes from 0A to 1A, setting force of the spring changes, as well. As the result, the specified
median of the pump delivery volume switching point changes as shown in the diagram. As for the front
pump side, it will change in the range of 0.98 to 2.45 MPa {10 to 25 kg/cm2} and as for the rear pump side,
it will change in the range of 1.08 to 2.55 MPa {11 to 26 kg/cm2}.
PC360LC-10 10-55
Main pump
Front pump
Rear pump
10-56 PC360LC-10
Main pump
Operation (PC300-C2J0-044-K-00-A)
When control valve is in the NEUTRAL position
• The LS valve is a 3-way selector valve, and LS pressure (PLS) (actuator load pressure) on the outlet of
control valve is transmitted to spring chamber (B), and pump delivery pressure (PP) is transmitted to port
(H) of sleeve (8).
• Magnitude of the force resulting from this LS pressure (PLS), force of spring (4) and the pump delivery
pressure (self pressure) (PP) determine the position of spool (6).
• However, magnitude of the output pressure (PSIG) (called the LS selector pressure) of the EPC valve for
the LS valve entering port (G) also changes the position of spool (6). (Setting force of the spring is
changed.)
• Before the engine is started, servo piston (12) is pushed to the left. (See the following figure.)
• If the control lever is in the neutral position when the engine is started, LS pressure (PLS) is set to 0 MPa
{0 kg/cm2}. (It is interconnected to the drain circuit via the control valve spool)
• Spool (6) is pushed to the right, and port (C) and port (D) will be connected.
• Pump pressure (PP) is conducted to the larger diameter end of the pump from the port (K).
• The same pump pressure (PP) is conducted to the smaller diameter end of the pump at the port (J).
• According to the area difference of servo piston (12), the servo piston is moved to the right, in the direction
which makes the swash plate angle minimum. (See the previous figure.)
PC360LC-10 10-57
Main pump
When pump delivery is increased
• When the difference between pump delivery pressure (PP) and LS pressure (PLS), in other words, LS
differential pressure (dPLS) decreases (for example, when the control valve open area increases and
pump delivery pressure (PP) decreases), the combined force of LS pressure (PLS) and the force of spring
(4) pushes spool (6) to the left.
• As spool (6) moves, ports (D) and (E) are interconnected and also connected to the PC valve.
• Since the PC valve and drain port are connected, the pressure between ports (D) and (K) becomes drain
pressure (PT). (PC valve operation will be explained later.)
10-58 PC360LC-10
Main pump
• The pressure on the large diameter piston side of servo piston (12) becomes drain pressure (PT), and
pump pressure (PP) is constantly applied to port (J) on the small diameter side. Accordingly, servo piston
(12) is pushed to the left and the swash plate is moved to increase the delivery.
• At this time, when the output pressure from the EPC valve for the LS valve enters port (G), a force is
applied on piston (7) to move the piston to the right.
• If piston (7) is pushed to the right, setting force of spring (4) is weakened, changing the LS differential
pressure (dPLS) [Difference between oil pressures (PLS) and (PP)] when ports (D) and (E) of spool (6)
are connected.
When pump delivery is decreased
• When servo piston (12) moves to the right (the direction in which pump delivery reduces) and LS
differential pressure (dPLS) increases (for example, when the control valve open area decreases and
pump delivery pressure (PP) increases), the force caused by pump delivery pressure (PP) pushes spool
(6) to the right.
• The movement of spool (6) transmits pump delivery pressure (PP) to the large diameter end of the piston
through port (C), port (D) and port (K).
• Although pump delivery pressure (PP) is applied to port (J) on the small diameter piston side, servo piston
(12) is pushed to the right by the area difference between the large diameter piston side and small
diameter piston side of servo piston (12). As the result, the swash plate angle becomes smaller.
• When the LS set selector pressure (PSIG) enters port (G), the spring (4) setting force is weakened.
PC360LC-10 10-59
Main pump
When servo piston is balanced
• The symbols (A1), (A0) and (PEN) represent the area receiving the pressure at the large diameter end of
the piston, the area receiving the pressure at the small diameter end and the pressure conducted to the
large diameter end of the piston, respectively.
• When the force exerted by main pump pressure (PP) of the LS valve is balanced with the combined force
exerted by LS pressure (PLS) and spring (4), and the relationship becomes (A0) x (PP) = (A1) x (PEN),
servo piston (12) stops in that position.
• The swash plate of the pump is held at the intermediate position. [Spool (6) is stopped at a position where
the opening area from port (D) to port (E) and the distance from port (C) to port (D) is almost the same.]
• The relation between the areas receiving the pressure at both ends of servo piston (12) is (A0) : (A1) = 3 :
5, and the pressures transmitted to both ends of the piston when the piston is balanced is (PP) : (PEN) C 5
: 3.
• The force of spring (4) is adjusted so that spool (6) can be balanced at the specified center when (PP) -
(PLS) = 2.45 MPa {25 kg/cm2} at the front pump side and (PP)–(PLS)=2.55 MPa {26 kg/cm 2} at the rear
pump side.
• If (PSIG) [Output pressure of LS-EPC valve, 0 to 2.9 MPa {0 to 30 kg/cm 2}] is input to port (G), the position
of the balanced stop is changed. The front pump side will be moved in the range of (PP) – (PLS) = 2.45 to
0.98 MPa {25 to 10 kg/cm2} and the rear pump will be moved in the range of (PP) – (PLS) = 2.55 to 1.08
MPa {26 to 11 kg/cm2} in proportion to (PSIG) pressure.
10-60 PC360LC-10
Main pump
PC valve (PC300-C2K0-041-K-00-A)
PC: Abbreviation for Pressure Compensation
PA: Pump port

PA2: Pump pressure pilot port
PDP: Drain port
PM: Mode selector pressure pilot port
PPL: Control pressure output port (to LS valve)
1. Plug
2. Servo piston assembly
3. Pin
4. Spool
5. Retainer
6. Seat
7. Cover
8. Wiring
Function (PC300-C2K0-042-K-00-A)
• The PC valve limits the oil flow to a certain level (depends on the delivery pressure) even if the travel of
the control valve is increased extremely. This is to ensure the horsepower absorbed by the pump not to
exceed the engine horsepower, when pump delivery pressures (PP1) (self pressure) and (PP2) (other
pump's pressure) are high.
• If the pump delivery pressure increases due to increased load during work, this valve decreases the pump
delivery.
• And if the pump delivery pressure goes low, it increases the pump delivery.
• The relation between the average delivery pressure of front and rear pumps [(PP1) + (PP2)] / 2 and pump
delivery (Q) is as shown in the following figure, as a parameter for each current (X) value applied to the PC
- EPC valve solenoid.
• The controller continues counting the actual engine speed.
• If the engine speed is slowed down due to increased load, the controller reduces the pump delivery to
recover the speed.
• When the load increases and the engine speed decreases below a preset value, the controller increases
the command current to the PC-EPC valve solenoid depending on the amount of engine speed decrease,
to decrease the swash plate angle.
PC360LC-10 10-61
Main pump
Operation (PC300-C2K0-044-K-00-A)
When the pump controller is normal
When load on the actuator is small and pump pressures (PP1) and (PP2) are low
Work of PC-EPC valve solenoid (1)

• Command current (X) from the pump controller flows to the PC-EPC valve solenoid (1).
• This command current (X) acts on the PC-EPC valve to generate signal pressure to vary the force pushing
piston (2).
10-62 PC360LC-10
Main pump
• Spool (3) stops at a position when the combined forces of springs (4) and (6), pump pressure (PP1) (self
pressure), and pump pressure (PP2) (other pump's pressure) acting on spool (3) are balanced.
• Depending on this position, the pressure output from the PC valve [port (C) pressure] varies.
• The amperage of the command current (X) depends on the type of work (lever operation), work mode
selection, engine speed setting, and the actual engine speed.
a Other pump's pressure denotes the pressure of the pump situated on the opposite side.
For the front pump pressure, the other pump's pressure is that of the rear pump. And for the rear pump
pressure, the other pump's pressure is that of the front pump.
Action of spring
• The spring forces of springs (4) and (6) in the PC valve depends on the position of the swash plate.
• When servo piston (9) moves to the right, spring (6) is compressed.
• When the piston moves further to the right, the piston comes in contact with seat (5) and spring (6) is fixed.
• Then, only spring (4) operates.
• When servo piston (9) compresses or decompresses springs (4) and (6), the spring load varies.
• When the command current (X) input to PC-EPC valve solenoid (1) varies, the thrust pushing piston (2)
varies.
• The spring loads of springs (4) and (6) are also varied by the PC-EPC valve solenoid command current
(X).
• Port (C) on the PC valve is connected to port (E) on the LS valve.
• Self pressure (PP1) enters the small diameter side of servo piston (9) and port (B), and other pump's
pressure (PP2) enters port (A).
• When pressures (PP1) and (PP2) are low, spool (3) is on the left.
• Port (C) and port (D) are connected, and the pressure entering the LS valve will be drain pressure (PT).
PC360LC-10 10-63
Main pump
• When port (E) of the LS valve is connected to port (G), the pressure from port (J) entering the large
diameter side of the piston becomes drain pressure (PT), and servo piston (9) moves to the left.
• The pump delivery goes to increase.
• Springs (4) and (6) extend according to the movement of servo piston (9), and the reaction force of spring
decreases.
• When the reaction force of spring decreases, spool (3) moves to the right. Ports (C) is disconnected from
port (D), and pump delivery pressure port (B) is connected to port (C).
• Since the pressure in port (C) and the pressure at the large diameter side of the piston increase, servo
piston (9) stops moving to the left.
• Accordingly, the stop position (= pump delivery) of servo piston (9) is determined by the position where the
thrust caused by pressures (PP1) and (PP2), the thrust generated by the PC-EPC valve solenoid, and the
force of springs (4) and (6) acting on the spool (3) are balanced.
When load on the actuator is large and pump pressures (PP1) and (PP2) are high
Outline
• When the load is large and the pump delivery pressures (PP1) and (PP2) are high, the thrust moving
spool (3) to the right increases, and spool (3) comes to a position as shown above.
• The pressure from port (C) to the LS valve becomes approximately half of pump pressure (PP2), because
a part of the pressure from port (B) flows through the LS valve and port (C) to port (D), as shown above.
• When spool (3) moves to the left, the openings of ports (C) and (D) widen.
• The pressure in port (C) (=J) decreases, and the movement of servo piston (9) to the right stops.
• Servo piston (9) will stop at a position further to the right than the position when pump pressures (PP1)
and (PP2) are low.
10-64 PC360LC-10
Main pump
Operation
• When ports (E) and (G) of the LS valve are connected, the pressure enters from port (J) to the large
diameter side of servo piston (9), and servo piston (9) stops moving.
• When pump pressure (PP2) increases more and spool (3) moves further to the right, pump pressure (PP1)
flows to port (C) to minimize the pump delivery.
• When servo piston (9) moves to the right, springs (4) and (6) are compressed, and spool (3) is pushed
back.
• The relation between the average pump pressure [(PP1)+(PP2)]/2 and servo piston (9) position are
plotted as a bent line because two springs (4) and (6) are used.
• The relationship between the average pump pressure (PP1 + PP2)/2 and average pump delivery (Q)
becomes as shown below.
• When the command current (X) input to PC-EPC valve solenoid (1) increases, the plotted line indicating
the relation between the average pump pressure (PP1+PP2)/2 and average pump delivery (Q) makes
parallel translation by a distance proportional to the PC-EPC valve solenoid thrust.
• Since PC-EPC valve solenoid (1) thrust is added to the thrust pressing spool (3) to the right, the curve
indicating relation between the average pump pressure (PP1+PP2)/2 and average pump delivery (Q)
shifts from (A) to (B) as the command current (X) is increased.
PC360LC-10 10-65
Main pump
When the pump controller malfunctions and the emergency pump drive switch is at the ON position
When load on the main pump is small
• If the pump controller fails, turn "ON" the emergency pump drive switch and select the resistor side.
• In this case, power must be taken directly from the battery, however, a resistor is needed to control the
current supplied to PC-EPC valve solenoid (1).
• Since the current is constant, the thrust applied to piston (2) is constant.
• When main pump pressures (PP1) and (PP2) are low, the combined force of PC-EPC valve solenoid (1)
thrust and the pump pressure is smaller than the force of springs. Spool (3) stays balanced at the left.
• Port (C) is connected to port (D) at drain pressure, and the pressure at the large diameter side of servo
piston (9) comes to drain pressure (PT) through the LS valve.
• Since the pressure at the small diameter side of the piston is large, servo piston (9) moves in the direction
to increase the delivery.
10-66 PC360LC-10
Main pump
When load on the main pump is large
• As mentioned before, when the emergency pump drive switch is turned "ON", the command current (X)
sent to PC-EPC valve solenoid (1) is constant.
• Therefore, the thrust applied by piston (2) to spool (3) comes to constant.
• When main pump pressures (PP1) and (PP2) increase, spool (3) moves to a position further to the right
than when the main pump load is small, and stays balanced as shown above.
• Since the pressure from port (B) is transmitted into port (C), servo piston (9) moves to the right (delivery
decreases), and stops at a position further to the right than when the pump load is small.
• When the emergency pump drive switch is turned "ON", the curve indicating the relation between the
pump pressure (PP) and delivery (Q) is plotted in accordance with the current supplied through the
resistor to the PC-EPC valve solenoid.
• When the emergency pump drive switch is turned "ON", the curve is plotted as (B), which is shifted toward
the left than curve (A) for a normal pump controller.
PC360LC-10 10-67
Main pump
10-68 PC360LC-10
Main pump
LS (PC)-EPC valve (PC300-C2M0-041-K-00-A)

EPC: Abbreviation for Electromagnetic Proportional Control
C: To LS(PC) valve
P: From self-pressure reducing valve
T: To hydraulic tank
1. Connector
2. Coil
3. Valve body
4. Spring
5. Spool
6. Rod
7. Plunger
PC360LC-10 10-69
Main pump
Function (PC-C2M0-042-K-00-A)
• The EPC valve consists of the proportional solenoid and the hydraulic valve.
• When the EPC valve receives signal current (i) from the controller, it develops EPC output pressure
proportional to the amperage of the current and supplies the pressure to the control valve.
10-70 PC360LC-10
Main pump
Operation (PC300-C2M0-044-K-00-A)
When signal current is zero amp (Coil is de-energized)
• When the signal current from the controller is not flowing through coil (2), coil (2) is de-energized.
• Spool (5) is pushed to the left side by spring (4).
• Port (P) is closed, and the pressurized oil from the self pressure reducing valve does not flow to the LS
(PC) valve.
• The pressurized oil from the LS (PC) valve flows through port (C) and then port (T), and is drained to the
tank.
PC360LC-10 10-71
Main pump
When signal current is minute (Coil is energized)
• When a small signal current flows through coil (2), coil (2) is energized and a thrust pushing plunger (7) to
the right is generated.
• Rod (6) pushes spool (5) to the right, and the pressurized oil flows from port (P) to port (C).
• The pressure at port (C) increases and the total of the force applied to the surface of spool (5) and the
reaction force exerted by spring (4) becomes larger than the thrust of plunger (7).
• Spool (5) is pushed to the left, and ports (P) and (C) are blocked.
• Port (C) connects to port (T).
• Spool (5) moves to a position where the thrust of plunger (7) becomes equal to the total of the force
exerted by pressure at port (C) and the reaction force exerted by spring (4).
• The circuit pressure between the EPC valve and LS (PC) valve is controlled in proportion to the amperage
of signal current.
10-72 PC360LC-10
Main pump
When signal current is maximum (Coil is energized)
• Coil (2) is energized when signal current is supplied to coil (2).

• As the amperage of signal current is maximum, the thrust of plunger (7) is also maximized.
• Spool (5) is pushed to the right by rod (6).
• The pressurized oil flows from port (P) to port (C) at the maximum rate, and the circuit pressure between
the EPC valve and LS (PC) valve is maximized.
• Port (T) closes, and no pressurized oil flows to the tank.
PC360LC-10 10-73
Control valve
Control valve (PC300-C030-041-K-00-A)
a In this section, only the 8-spool valve (6-spool valve + arm Hi and boom Hi valve + service valve) is
shown.
A1: To bucket cylinder bottom
10-74 PC360LC-10
Control valve
A2: To L.H. travel motor

A3: To boom cylinder bottom
A4: To swing motor
A5: To R.H. travel motor
A6: To arm cylinder head
A-1: To boom cylinder bottom
A-2: To attachment 1
B1: To bucket cylinder head
B2: To L.H. travel motor
B3: To boom cylinder head
B4: To swing motor
B5: To R.H. travel motor
B6: To arm cylinder bottom
B-1: To arm cylinder bottom
B-2: To attachment 1
BP1: Boom raising PPC output pressure
BP5: From 2-stage safety solenoid valve
BP6: From attachment selector solenoid valve
IS1: From controller
IS2: From controller
CN: From controller
P1: From bucket PPC and EPC valves
P2: From bucket PPC and EPC valves
P3: From L.H. travel PPC valve
P4: From L.H. travel PPC valve
P5: From boom PPC and EPC valves
P6: From boom PPC and EPC valves
P7: From swing PPC and EPC valves
P8: From swing PPC and EPC valves
P9: From R.H. Travel PPC valve
P10: From R.H. Travel PPC valve
P11: From arm PPC and EPC valves
P12: From arm PPC and EPC valves
P-3: From service 1 and PPC valves
P-4: From service 1 and PPC valves
PLS1: To front pump control
PLS2: To rear pump control
PP1: From front pump
PP2: From rear pump
PP1S: Pressure sensor mounting port
PP2S: Pressure sensor mounting port
PPS1: To front pump control
PPS2: To rear pump control
PR: To solenoid valve, PPC valve, and EPC valve
PST: From travel junction valve solenoid valve
PX1: From 2-stage relief solenoid valve
PX2: From 2-stage relief solenoid valve
PC360LC-10 10-75
Control valve
T: To tank
T1: To tank
TS: To tank
TSW: To swing motor S-port (suction side)
1. 6-spool valve
2. Cover A
3. Cover B
4. Boom Hi and arm Hi valve
5. Service valve 1
7. Boom drift prevention valve
8. Quick return valve
9. Boom Hi valve check valve
10-76 PC360LC-10
Control valve
1. Pressure compensation valve (Arm OUT)

2. Pressure compensation valve (R.H. travel REVERSE)
3. Pressure compensation valve (LEFT swing)
4. Pressure compensation valve (Boom RAISE)
PC360LC-10 10-77
Control valve
5. Pressure compensation valve (L.H. travel REVERSE)

6. Pressure compensation valve (Bucket CURL)
7. Pressure compensation valve (Boom Hi raise)
8. Pressure compensation valve (Service 1)
9. Pressure compensation valve (Arm Hi IN)
10. Pressure compensation valve (Bucket DUMP)
11. Pressure compensation valve (L.H. travel FORWARD)
12. Pressure compensation valve (Boom LOWER)
13. Pressure compensation valve (RIGHT swing)
14. Pressure compensation valve (R.H. travel FORWARD)
15. Pressure compensation valve (Arm IN)
17. Unload valve
19. Spool (Service 1)
20. Spool (Arm Hi)
21. Spool (Bucket)
22. Spool (L.H. travel)
23. Spool (Boom)
24. Spool (Swing)
25. Spool (R.H. travel)
26. Spool (Arm)
27. Spool (Boom Hi)
10-78 PC360LC-10
Control valve
1. Suction valve (Arm OUT)

2. Suction valve (R.H. travel REVERSE)
3. Suction valve (Boom RAISE)
4. Suction valve (L.H. travel REVERSE)
5. Suction safety valve (Service 1)
6. 2-stage suction safety valve (Service 1)
7. Suction safety valve (Arm Hi IN)
8. Suction safety valve (bucket DUMP)
9. Suction valve (L.H. travel FORWARD)
PC360LC-10 10-79
Control valve
10. 2-stage suction safety valve (Boom LOWER)

11. Suction valve (R.H. travel FORWARD)
12. Suction safety valve (Arm IN)
13. LS shuttle valve (Arm)
14. LS shuttle valve (R.H. travel)
15. LS select valve
16. LS shuttle valve (Boom)
17. LS shuttle valve (Left travel)
18. LS shuttle valve (Bucket)
19. LS shuttle valve (Service 1)
20. LS check valve
21. Pressure relief plug
22. LS line slow return valve
10-80 PC360LC-10
Control valve
1. Unload valve
2. Suction safety valve for hydraulic drift prevention valve (boom RAISE and arm OUT)
4. Variable back pressure valve
PC360LC-10 10-81
Control valve
Arm valve
5. Arm hydraulic drift prevention valve (if equipped)
6. LS shuttle valve
7. Pressure compensation valve (IN)
8. Spool
9. Suction safety valve (IN)
10. Regeneration circuit check valve
11. Suction valve (OUT)
12. Pressure compensation valve (OUT)
R.H. travel valve

13. LS shuttle valve
14. Pressure compensation valve (FORWARD)
15. Spool
16. Suction valve (FORWARD)
17. Suction valve (REVERSE)
18. Pressure compensation valve (REVERSE)
Swing valve
19. LS select valve
20. Pressure compensation valve (R.H.)
21. Spool
22. Pressure compensation valve (L.H.)
10-82 PC360LC-10
Control valve
1. Return spring
2. Merge-divider valve (for LS)
3. Valve (Sequence valve)
4. Spring (Sequence valve)
PC360LC-10 10-83
Control valve
5. Merge-divider valve (Main)

6. Return spring
Boom valve
8. LS shuttle valve
9. Pressure compensation valve (LOWER)
10. Spool
11. Suction safety valve (LOWER)
12. Regeneration circuit check valve
13. Suction valve (RAISE)
14. Pressure compensation valve (RAISE)
L.H. travel valve

15. Merge-divider valve (travel junction valve)
16. Return spring
18. Pressure compensation valve (REVERSE)
19. Spool
20. Suction valve (REVERSE)
21. Suction valve (FORWARD)
22. Pressure compensation valve (FORWARD)
Bucket valve
24. Pressure compensation valve (DUMP)
25. Spool
26. Suction safety valve (DUMP)
27. Suction safety valve (CURL)
28. Pressure compensation valve (CURL)
10-84 PC360LC-10
Control valve
Boom Hi and arm Hi valve

1. Boom Hi check valve
2. Quick return valve
3. Pressure compensation valve (Arm Hi IN)
PC360LC-10 10-85
Control valve
4. Arm Hi spool
5. Suction safety valve (arm Hi IN)
6. Boom Hi spool
7. Pressure compensation valve (Boom Hi RAISE)
Service valve
8. LS shuttle valve
9. Pressure compensation valve
10. Spool
11. 2-stage suction safety valve
12. Suction safety valve
13. Unload valve
15. LS bypass plug
Structure
• The control valves of the following types are set.
8-spool valve (6-spool valve + arm Hi and boom Hi valve + service valve)
• The control valve consists of a 6-spool valve (integrated structure), boom Hi and arm Hi valve, and a set of
service valves. A merge-divider valve, a variable back pressure valve, a boom hydraulic drift prevention
valve, and an arm quick return valve are installed to it.
• Since all the valves are assembled together with connecting bolts and their passes are connected to each
other inside the assembly, the assembly is compact and easy to maintain.
• With one spool provided for one work equipment, this control valve is simple in structure.
10-86 PC360LC-10
Control valve
Hydraulic circuit diagram and valve names (PC300-C030-054-K-00-A)
1. Arm valve
2. R.H. travel valve
PC360LC-10 10-87
Control valve
3. Swing valve
4. Boom valve
5. L.H. travel valve
6. Bucket valve
7. Boom Hi and arm Hi valve
8. Service valve
9. Arm valve spool
10. R.H. travel valve spool
11. Swing valve spool
12. Boom valve spool
13. L.H. travel valve spool
14. Bucket valve spool
15. Boom Hi valve spool
16. Arm Hi valve spool
17. Service spool
19. Suction valve
20. Check valve (for boom regeneration circuit)
21. Check valve (for arm regeneration circuit)
22. Merge-divider EPC valve (for LS spool)
23. Merge-divider EPC valve (for main spool)
25. LS bypass plug
26. LS select valve
28. Arm quick return valve
29. Arm hydraulic drift prevention valve (if equipped)
30. Self-pressure reducing valve
31. Travel junction valve
32. Variable back pressure valve
33. Variable back pressure solenoid valve
35. Main relief valve (for boom, L.H. travel, bucket, and attachment circuits)
Set pressure: 36.1 ± 0.25 MPa {367.5 ± 2.5 kg/cm2}
When one-touch power max. switch is set to the ON position: 38.2 ± 0.25 MPa {389.5 ± 2.5 kg/cm 2}
36. Main relief valve (for arm, right travel and swing circuits)
Set pressure: 36.1 ± 0.25 MPa {367.5 ± 2.5 kg/cm2}
When one-touch power max. switch is set to the ON position: 38.2 ± 0.25 MPa {389.5 ± 2.5 kg/cm 2}
37. Unload valve (for boom, L.H. travel, bucket, and attachment circuits)
Cracking pressure: 3.1 MPa {32 kg/cm2}
38. Unload valve (for arm, R.H. travel, and swing circuits)
Cracking pressure: 3.1 MPa {32 kg/cm2}
Set pressure: 17.2 ± 0.5 MPa {175 ± 5 kg/cm2}
10-88 PC360LC-10
Control valve
1st stage set pressure: 28.4 ± 0.5 MPa {290 ± 5 kg/cm2}

2nd stage set pressure: 14.7 ± 0.5 MPa {150 ± 5 kg/cm2}
1st stage set pressure: 20.1 ± 0.5 MPa {205 ± 5 kg/cm2}
2nd stage set pressure: 17.2 ± 0.5 MPa {175 ± 5 kg/cm2}
43. Suction safety valve for hydraulic drift prevention valve
Unload valve (PC220-PQD5-041-K-00-A)
1. LS circuit
2. Valve
3. Pump circuit
4. Tank circuit
5. Spring
Function (PC220-PQD5-042-K-00-A)
• When all control valves are at HOLD, this valve serves to drain as same amount of oil as the pump
delivery with swash plate angle at the minimum.
• The pump pressure becomes the pressure corresponding to the set load of spring (5) in the valve (referred
to as P1).
• Since LS pressure is drained from LS bypass valve, LS pressure C tank pressure C 0 MPa {0 kg/cm2}.
Operation (ALL-PQD5-044-K-00-A)
• Pressure of pump circuit (3) is received by the end of valve (2).
• Since the control valve is in NEUTRAL position, pressure of LS circuit (1) is 0 MPa {0 kg/cm 2}.
• Pressurized oil of pump circuit (3) stops at valve (2), and the pressure rises as no relief is available.
• If this pressure grows larger than the force of spring (5), valve (2) moves to the left.
• Ports (b) and (c) are interconnected, and the pump pressurized oil flows to tank circuit (4).
• The pressurized oil of LS circuit (1) passes from orifice (a) through port (c) and is drained to tank circuit
(4).
• When this valve is actuated, the LS pressure becomes nearly equal to the tank pressure.
• Since the pump delivery pressure - LS circuit pressure during unloading is larger than pump LS control
pressure, the signal is output to minimize the pump swash plate angle.
• During operation (when a given work is done within the delivery available with the minimum swash plate
angle), the delivery pressure corresponding to the minimum pump swash plate angle is set to LS pressure
+ P1 pressure.
• The LS differential pressure (dPLS) with the swash plate angle at the minimum becomes P1 pressure.
Operation of relief valve

• When cylinder reaches its stroke end, main relief valve opens.
• Pump delivery (Q) is relieved to the tank. (For details, see " System diagram" of "Structure of CLSS".
PC360LC-10 10-89
Control valve
• Since the pump delivery pressure (PP) and LS pressure (PLS) do not flow neither to the upstream nor
downstream, they become approximately the same and LS differential pressure (dPLS) becomes 0 MPa
{0 kg/cm2}.
• As LS differential pressure (dPLS) is lower than the LS set pressure of LS valve, LS valve operates to
make the pump swash plate angle maximum.
• Mechanically, operation of PC valve has priority over that of LS valve.
• The pump is maintained at the minimum swash plate angle due to PC valve cut-off function.
Introduction of LS pressure (PC220-C2A4-041-K-00-A)

1. Main pump
2. Main spool
4. Valve
5. Check valve
6. LS circuit
7. LS shuttle valve
10-90 PC360LC-10
Control valve
Function (PC220-C2A4-042-K-00-A)
• The upstream pressure (spool meter-in downstream pressure) of pressure compensation valve (3) is
transmitted and led to LS shuttle valve (7) as LS pressure.
• Connected to actuator port (B) through valve (4), and makes LS pressure C actuator load pressure.
• In main spool (2), leading hole (a) with a small diameter also acts as an orifice.
• LS pressure works as source pressure when closing unload vale while control lever is operated, and this
pressure also functions as operating pressure when pressure compensation valve is compensated.
Operation (PC220-C2A4-044-K-00-A)
• When main spool (2) is operated, the pump pressure is transmitted to port (c) through leading hole (a) and
is led to LS circuit.
• When the pump pressures rises to reach the load pressure of port (B), check valve (5) opens and the
pressurized oil flows.
LS bypass plug (PC220-PNSH-041-K-00-A)
1. Main pump
2. Main spool
4. LS shuttle valve
5. LS bypass plug
6. LS circuit
Function (ALL-PNSH-042-K-00-A)
• This valve relieves the residual pressure in LS pressure circuit (6) from orifices (a) and (b).
• Slows down the rising rate of LS pressure to prevent a sudden change of hydraulic pressure.
• Depending on the bypass flow from LS bypass plug (5), pressure loss is generated due to the circuit
resistance from orifice (c) of main spool (2) to LS shuttle valve (4).
• Effective LS differential pressure drops to improve a dynamic stability of the actuator.
PC360LC-10 10-91
Control valve
Pressure compensation valve (PC300-L6D0-040-K-00-A)

When the work equipment is operated independently and the load pressure is the maximum
(When the load pressure is higher than that of other work equipment during a combined operation)
1. Main pump
2. Valve
3. Shuttle valve
4. Piston
5. Spring
6. LS shuttle valve
Function
• Pressure compensation valve works as the load check valve.
• If the pump pressure (LS pressure) is lower than the load pressure at port (c), shuttle valve (3) in pressure
compensation valve piston (4) interconnects spring chamber (E) and port (C).
• The force of spring (5) operates piston (4) and valve (2) to the closing direction.
Integrated pressure compensation valve

• When a high peak pressure or continuous and repetitive peak pressure (as in breaker operation) is
generated in the actuator circuit, valve (2) may collide with valve chamber seat (C), producing high stress
in the parts.
• To prevent this, a pressure compensation valve with integrated valve (2) and piston (4) is used.
• With this machine, this valve is adopted for the travel valve, bucket valve (cylinder bottom), arm Hi valve
(cylinder bottom), and the service valve.
• If high peak pressure is generated at port (C), valve (7) does not collide with the valve chamber.
• With a bucket valve, etc., port (C) and spring chamber (E) are designed to interconnect before valve (7) is
seated.
10-92 PC360LC-10
Control valve
When compensated
(When the load pressure is lower than that of other work equipment during a combined operation)
Function
• The pressure compensation valve is closed by the LS pressure of port (D), and the spool meter-in
downstream pressure of port (B) becomes equivalent to the maximum pressure of other work equipment.
• Since the spool meter-in upstream pressure at port (A) is the pump pressure, the spool meter-in
differential pressure [upstream pressure port (A) pressure] - downstream pressure [port (B) pressure]
becomes equal to all the spools in operation.
• Pump flow is divided according to the ratio of the meter-in opening areas.
Operation
• Spring chamber (E) is interconnected to port (D).
• Piston (4) and valve (2) are moved in the closing direction (to the right) by the LS circuit pressure of port
(F) from other work equipment.
• Valve upstream pressure (= spool meter-in downstream pressure) of port (B) is controlled by the LS
pressure.
PC360LC-10 10-93
Control valve
Area ratio of pressure compensation valve
Function
• The condition of oil flow division changes according to the area ratio of pressure compensation valve
portions (A1) and (A2). Area ratio = (A2)/(A1)
• When the area ratio is equal to 1: As the spool meter-in downstream pressure is equal to the maximum
load pressure, the oil flow is divided in the same ratio as the opening area ratio.
• When the area ratio is more than 1: As the spool meter-in downstream pressure is higher than the
maximum load pressure, the oil flow is divided in a ratio smaller than the opening area ratio.
• When area ratio is below 1: As the spool meter-in downstream pressure is smaller than the maximum load
pressure, the oil flow is divided in a ratio larger than the opening area ratio.
10-94 PC360LC-10
Control valve
Shuttle valve in pressure compensation valve (PC220-L6D3-040-K-00-A)

When holding pressure at port (A) becomes higher than LS pressure in spring chamber (B)
1. Main pump
2. Valve
3. Shuttle valve
4. Piston
Operation
• Shuttle valve (3) is pressed to the right side by the pressure of port (A). As a result, port (A) is
disconnected from port (C).
• Holding pressure at port (A) is transmitted to the spring chamber (B) to push piston (4) to the left so that
piston (4) is not separated from valve (2).
PC360LC-10 10-95
Control valve
When traveling
Structure
• Since no holding pressure is generated at port (A) of the travel circuit, a pressure compensation valve
without shuttle valve (5) is adopted.
10-96 PC360LC-10
Control valve
Boom regeneration circuit (PC220-L511-040-K-00-A)

When cylinder head pressure is lower than bottom pressure (hydraulic drift, etc.)
1. Main pump
2. Boom valve spool
5. Suction valve
6. Check valve
7. LS shuttle valve
Function
• The regeneration circuit is installed across the cylinder bottom and cylinder head to increase flow to the
cylinder head when the boom is lowered.
Operation
• When the cylinder head pressure is lower than the bottom pressure, some of pressurized oil (A) from the
cylinder bottom flows to drain circuit (B) from the notch of boom spool (2).
• The remaining oil flows to regeneration circuit (C), opens check valve (6) and flows to the cylinder bottom
through circuit (D).
• Flow from regeneration circuit (C) merges into the oil from pump (1) in circuit (E).
PC360LC-10 10-97
Control valve
When cylinder head pressure is higher than bottom pressure (digging operation, etc.)
Function
• Check valve (6) provided to regeneration circuit (C) closes to shut off the flow from the cylinder bottom to
the head.
10-98 PC360LC-10
Control valve
Arm regeneration circuit (PC220-L911-040-K-00-A)

When cylinder head pressure is higher than bottom pressure
1. Main pump
2. Arm valve spool
5. Suction valve
6. Check valve
7. LS shuttle valve
Function
• The regeneration circuit installed between the cylinder head and cylinder bottom increases the oil flowing
to the cylinder bottom (pump delivery + regeneration flow) during arm IN operation in order to accelerate
the cylinder.
Operation
• When the cylinder head pressure is higher than the bottom pressure, part of pressurized oil (A) from the
cylinder head flows to drain circuit (B) through the notch of arm spool (2).
• The remaining oil flows to the regeneration circuit (C), opens check valve (6), and flows to the cylinder
bottom through circuit (D).
• Flow from regeneration circuit (C) merges into the oil from pump (1) in circuit (E).
PC360LC-10 10-99
Control valve
When cylinder head pressure is lower than bottom pressure
Function
• Check valve (6) installed to regeneration circuit (C) closes and shuts off the oil flowing from the cylinder
head to the bottom.
10-100 PC360LC-10
Control valve
Merge-divider valve (PC220-PP30-040-K-00-A)

When oil flowing from two pumps are merged [pump merge-divider valve changeover signals (IS1)
and (IS2) are OFF]
1. Main spool
2. Spring
3. LS spool
4. Spring
5. LS circuit (for bucket valve)
6. LS circuit (for bucket valve)
7. LS circuit (for arm valve)
8. LS circuit (for arm valve)
9. Pump merge-divider EPC valve (for main spool changeover)
10. Pump merge-divider EPC valve (for LS spool changeover)
Function
• This valve merges the pressurized oil (P1) and (P2) from the two pumps or divides them (enables them to
flow to respective control valve groups).
• This valve merges or divides LS circuit pressures as well.
PC360LC-10 10-101
Control valve
Operation
• Since drive signal (IS1) of the EPC valve for the main spool is OFF, the output pressure of the pump
merge-divider EPC valve is 0 MPa {0 kg/cm2}.
• Main spool (1) is pressed to the right by spring (2). As a result, ports (E) and (F) are interconnected.
• Pressurized oil (P1) and (P2) discharged from the two pumps merge at ports (E) and (F), and flow to the
control valve which requires the oil.
• Since drive signal (IS2) of the EPC valve for LS spool (3) is also OFF, LS spool (3) is pressed to the right
by spring (4). As a result, ports (A) and (B) are interconnected and ports (B) and (C) are interconnected.
• The LS pressures transmitted from respective control valve spools through LS circuits (5), (6), (7), and (8)
are transmitted to all the pressure compensation valves.
When oil flowing from two pumps are divided [pump merge-divider valve changeover signals (IS1)
and (IS2) are ON]
Operation
• Since drive signal (IS1) of the main spool is ON, main spool (1) is moved to the left by the output pressure
from the pump merge-divider EPC valve. As a result, port (E) is disconnected from port (F).
• The pressurized oil from the two pumps are sent to respective control valve groups.
Pressure P1: To bucket, left travel, boom
Pressure P2: To swing, right travel, arm
• When drive signal (IS2) of the EPC valve for LS spool (3) becomes ON, LS spool (3) is also moved to the
left by the output pressure from the pump merge-divider EPC valve. As a result, ports (A) and (C) are
interconnected, and other ports remain disconnected from each other.
• The LS pressures transmitted from respective control valve spools through LS circuits (5), (6), (7), and (8)
are transmitted to respective control valves.
10-102 PC360LC-10
Control valve
LS selector valve (PC220-J6PA-041-K-00-A)
a The illustration shows the condition when the combined operation of swing and R.H. travel is performed.
[When pilot pressure (BP) is supplied]
1. Valve
2. Spring
3. Piston
4. Piston
5. Swing valve spool
6. R.H. travel valve spool
7. Arm valve spool
8. LS shuttle valve
9. LS circuit
Function (PC300-J6PA-042-K-00-A)
• This valve prevents the high LS pressure of the swing valve from entering the LS circuits of work
equipment valves when the swing and boom RAISE are in combined operation.
• This valve prevents high pressure generated at swing drive to improve operability of work equipment.
Operation (ALL-J6PA-044-K-00-A)
When pilot pressure (BP) is shut off

• Since pilot pressure (BP) is shut off, piston (3) is pressed to the left by force of spring (2).
• If the swing lever is moved, swing LS pressure (P1) passing through swing spool (5) enters port (A).
• Swing LS pressure (P1) presses valve (1) to the left, and port (A) and port (B) are interconnected.
• Swing LS pressure (P1) is transmitted from port (A) to LS shuttle valve (8) through port (B).
PC360LC-10 10-103
Control valve
When pilot pressure (BP) is supplied

• When pilot pressure (BP) is supplied, pilot pressure (BP) moves piston (3) to the right against the force of
spring (2).
• When piston (3) moves to the right, valve (1) disconnects ports (A) and (B).
• Since ports (A) and (B) are disconnected, swing LS pressure (P1) is not transmitted to LS shuttle valve
(8).
• Swing LS pressure (P1) cannot affect other LS circuits, even if it rises.
10-104 PC360LC-10
Control valve
Self-pressure reducing valve (PC220-PL30-042-K-00-A)

Function
• This valve serves to reduce the delivery pressure of main pump and provide it for solenoid valves, EPC
valves, etc. for use as the control pressure.
Operation (ALL-PL30-044-K-00-A)
When engine is stopped

• Poppet (11) is pressed against the seat by spring (12), so port (PR) is disconnected from port (TS).
• Valve (14) is pressed to the left by spring (13), so port (P2) is disconnected from (TS).
• Valve (7) is pressed to the left by spring (8), so port (P2) is disconnected from port (A2).
PC360LC-10 10-105
Control valve
10-106 PC360LC-10
Control valve
When load pressure (P2) is low

a When all control levers are in NEUTRAL position, or when load pressure (A2) is lower than output
pressure (PR) of the self-pressure reducing valve
• Force of spring (8) and the force exerted by the pressure (PR) (0 MPa {0 kg/cm 2}, when engine is stopped),
are applied to valve (7) in the direction to disconnect the circuit ports (P2) and (A2).
• When the pressurized oil flows in from port (P2), valve (7) balances at a position where [Force (Area fd x
Pressure P2) = Force of spring (8) + Force (Area fd x Pressure PR)] holds.
• The opening of valve (7) is adjusted so that pressure (P2) remains at a constant level higher than pressure
(PR).
• When pressure (PR) rises above the set pressure, poppet (11) opens.
• The pressurized oil flows from port (PR) to orifice (a) in spool (14), then flows to seal drain port (TS) from
the opening of poppet (11).
• Differential pressure generated across orifice (a) in spool (14) moves spool (14) in the direction that the
spool closes the opening between ports (P2) and (PR).
• Pressure (P2) is reduced to a constant pressure (the set pressure) by the opening and supplied for use as
pressure (PR).
PC360LC-10 10-107
Control valve
When load pressure (P2) is high

• As load pressure (A2) increases with the digging operation, etc, the pump delivery increases accordingly.
• Pressure (P2) increases, and [Force (Area fd x Pressure P2] becomes larger than [Force of spring (8) +
Force (Area fd x Pressure PR)]. As a result, valve (7) moves fully to the right.
• Since the area of the opening between ports (P2) and (A2) increases, the passage resistance reduces,
reducing the engine horsepower loss.
• When pressure (PR) rises above the set pressure, poppet (11) opens.
• The pressurized oil flows from port (PR) to orifice (a) in spool (14), then flows to seal drain port (TS) from
the opening of poppet (11).
• Differential pressure generated across orifice (a) in spool (14) moves spool (14) in the direction that the
spool closes the opening between ports (P2) and (PR).
• Pressure (P2) is reduced to a constant pressure (the set pressure) by the opening and supplied for use as
pressure (PR).
10-108 PC360LC-10
Control valve
When abnormally high pressure is generated

• If pressure (PR) of the self-pressure reducing valve becomes abnormally high, ball (16) contracts spring
(15) and separates from the seat.
• This allows the pressurized oil to flow to drain port (TS) from port (PR), lowering pressure (PR).
• As a result, components such as PPC valves and solenoid valves are protected from abnormally high
pressure.
PC360LC-10 10-109
Control valve
Travel junction valve (PC220-C6C0-042-K-00-A)

Function
• When travel control lever is operated for straight-travel, travel junction valve does not receive the pilot
pressure (PST) from travel junction solenoid valve, thus right and left travel circuits interconnect each
other, and equal amount of oil is supplied to right and left travel motors to secure straight-travel ability.
• When travel control lever is operated for turning, travel junction valve receives the pilot pressure (PST)
from travel junction solenoid valve, thus right and left travel circuits are shut off each other, and
independent amount of oil is supplied to right and left travel motors to secure turning ability.
10-110 PC360LC-10
Control valve
Operation (ALL-C6C0-044-K-00-A)
When pilot pressure (PST) is shut off (travel junction)
• If pilot pressure (PST) from the travel junction solenoid valve is shut off, travel junction spool (2) is pressed
back towards right by the force of spring (1). As a result, ports (PTL) and (PTR) are interconnected.
• If the oil flow rates to the R.H. and L.H. travel motors become different from each other, the oil flows
through the opening of travel junction spool (2) from port of higher pressure side to port of lower pressure
side supplying the difference of oil to the lower pressure side so that the oil flow rates to both motors will
be equalized.
PC360LC-10 10-111
Control valve
When pilot pressure (PST) is supplied (travel independent)
• When pilot pressure (PST) from the travel junction solenoid valve is supplied, travel junction spool (2)
compresses spring (1) to the left side and ports (PTL) and (PTR) are disconnected.
• The oil flow rate to both right and left motors becomes independent.
10-112 PC360LC-10
Control valve
Travel PPC shuttle valve (PC300-C6V1-042-K-00-A)
PPC: Abbreviation for Proportional Pressure Control
Function
• If arm IN operation is performed when the machine is traveling up a steep, the pilot pressure from the
travel PPC valve serves to restrict the travel of each spool of arm so that the oil flow rate to each cylinder
is restricted.
• To limit the travel of the arm spool, the pilot pressure from the travel PPC valve passes through the internal
circuit of control valves and acts on the spool.
Operation (PC300-C6V1-044-K-00-A)
When travel lever is in NEUTRAL
• The oil in the stroke limiting signal chamber (a) passes through orifices (5) and (6) of respective pistons (3)
and (4) built in the travel spring case, and then is drained through the travel PPC valve.
• When boom RAISE (or arm IN) operation is performed, spool (1) moves to the left until it contacts the end
face of spring case (2) (st0).
PC360LC-10 10-113
Control valve
Travel operation
• If the right REVERSE (or FORWARD) travel is performed, the pilot pressure from the travel PPC valve
moves spool (7) to the left (or right).
• Spool (7) pushes piston (3) to close orifice (5) and shut off stroke regulation signal chamber (a) and the
drain circuit of the travel PPC valve.
• At this time, the pilot pressure from the travel PPC valve passes through orifice (6) of piston (4) and acts
on the left end of piston (8) and pushes piston (8) to the right.
• When arm IN operation is performed, spool (1) moves to the left.
• Maximum stroke of the spool is limited to (st1) for the amount of movement (st2) of piston (8) to the right.
10-114 PC360LC-10
Control valve
Boom hydraulic drift prevention valve (PC220-L6C0-042-K-00-A)

Function
• While boom is not operated by the right work equipment control lever, the hydraulic drift prevention valve
prevents pressurized oil to leak from boom cylinder bottom through spool (1) to prevent the boom from
drifting hydraulically.
Operation (ALL-L6C0-044-K-00-A)
In boom "RAISE" operation
• When operating boom "RAISE", the pressurized oil from the control valve exerts a left-hand force on the
right side of ring-shaped area (S), of which outside diameter is poppet (5) diameter (d1) and of which
inside diameter is seat diameter (d2).
• The left-hand force on area (S) compresses spring (4) and moves poppet (5) to the left.
• As a result, the pressurized oil from the control valve passes through the opening of poppet (5) and flows
to the boom cylinder bottom.
PC360LC-10 10-115
Control valve
In boom "NEUTRAL" operation
• When the boom is operated to "NEUTRAL" position, the pressurized oil flowing inside poppet (5) through
orifice (a) of poppet (5) is stopped by pilot piston (2).
• The holding pressure of boom cylinder bottom exerts a right-hand force on the left side of ring-shaped
area (S), of which outside diameter is poppet (5) diameter (d1) and of which inside diameter is seat
diameter (d2).
• The combined force of right-hand force on area (S) and the spring force of spring (4) moves poppet (5) to
the right.
• The circuit from control valve to boom cylinder bottom shuts off, then the oil pressure of the boom cylinder
bottom side is kept.
10-116 PC360LC-10
Control valve
In boom "LOWER" operation
• When operating boom "LOWER", the pilot pressure from the PPC valve pushes pilot piston (2).
• The pressurized oil of the boom cylinder bottom flows from orifice (c) to drain port (T) through orifice (a)
and chamber (b).
• Chamber (b) inside poppet and drain port (T) are interconnected, and the pressure of chamber (b) drops.
• As the pressure of chamber (b) becomes less than the pressure of port (B), poppet (5) opens.
• As poppet (5) opens, the pressurized oil from port (B) flows to port (A) and then flows to the control valve.
PC360LC-10 10-117
Control valve
Arm hydraulic drift prevention valve (PC220-L9K0-042-K-00-A)
(if equipped)
Function
• While arm is not operated by the left work equipment control lever, the hydraulic drift prevention valve
prevents pressurized oil to leak from arm cylinder head through spool (1) to prevent the arm from drifting
hydraulically.
Operation (PC-L9K0-044-K-00-A)
In arm "OUT" operation
• During arm "OUT" operation, the pressurized oil from the control valve exerts a left-hand force on the right
side of area (S) of ring-shaped surface, of which outside diameter is equal to diameter (d1) of poppet (5)
and of which inside diameter is equal to seat diameter (d2).
• The left-hand force on area (S) compresses spring (4) and moves poppet (5) to the left.
• As a result, pressurized oil from the control valve flows to the arm cylinder head through the opening of
poppet (5).
10-118 PC360LC-10
Control valve
In arm "NEUTRAL" operation
• When the arm is operated to "NEUTRAL" position, the pressurized oil flowing inside poppet (5) through
orifice (a) of poppet (5) is stopped by pilot piston (2).
• The holding pressure of arm cylinder head exerts a right-hand force on the left side of ring-shaped area
(S), of which outside diameter is equal to diameter (d1) of poppet (5) and of which inside diameter is equal
to seat diameter (d2).
• The combined force of right-hand force on area (S) and the reaction force of spring (4) moves poppet (5)
to the right.
• The circuit from control valve to arm cylinder head shuts off, then the oil pressure of the arm cylinder head
side is kept.
PC360LC-10 10-119
Control valve
In arm "IN" operation
• When arm is operated "IN", the pilot pressure from the PPC valve pushes pilot piston (2).
• The pressurized oil of the arm cylinder head flows from orifice (c) to drain port (T) through orifice (a) and
chamber (b).
• Chamber (b) inside poppet and drain port (T) are interconnected, and the pressure of chamber (b) drops.
• As the pressure of chamber (b) becomes less than the pressure of port (B), poppet (5) opens.
• As poppet (5) opens, the pressurized oil from port (B) flows to port (A) and then flows to the control valve.
10-120 PC360LC-10
Control valve
Suction safety valve for hydraulic drift prevention valve (PC300-L9K2-044-K-00-A)

Operation when abnormally high pressure is generated
• If abnormally high pressure is generated in the boom cylinder bottom circuit, the pressurized oil in port (B)
opens check valve (6) to actuate suction safety valve (3).
• When the arm hydraulic drift prevention valve (optional) is installed to the arm cylinder head circuit, the
pressurized oil of the boom cylinder bottom circuit or arm cylinder head circuit, whichever has higher
pressure, opens check valve (6) or (6A) to actuate suction safety valve (3).
PC360LC-10 10-121
Control valve
Arm quick return valve (PC220-L9K1-042-K-00-A)

Function
• Large amount of oil is returned from the cylinder bottom when arm OUT operation is performed.
• The valve reduces this pressure loss.
Operation (PC300-L9K1-044-K-00-A)
In arm "OUT" operation
• In arm "OUT" operation, the pilot pressure from the PPC valve pushes pilot piston (1).
• The pressurized oil in chamber (b) inside the valve is drained through orifice (c).
• The pressurized oil of the arm cylinder bottom side flows from orifice (c) to drain port (T) through orifice (a)
and chamber (b).
• Chamber (b) and drain port (T) are interconnected, and the pressure of chamber (b) drops.
• If the pressure in chamber (b) drops lower than that of port (A), the force exerted on the pressure receiving
surface of [Area (S2) of fd2 (surface of seat diameter)] on the port (A) side exceeds the combined force of
the force exerted on the pressure receiving surface [Area (S1) of fd1] on the chamber (b) side of valve (2)
and the spring force.
• The result is, (Force exerted on surface of fd2 > Force exerted on surface of fd1 + Force of spring).
• Valve (2) is pressed to the left and pressurized oil flows from port (A) to port (B).
• The pressurized oil of the arm cylinder bottom side is drained directly to the tank from port (B).
10-122 PC360LC-10
Control valve
In arm "NEUTRAL" operation
• When the arm is operated from arm "OUT" to "NEUTRAL", the pilot pressure from PPC valve is shut off.
• The pressurized oil that flows in through orifice (a) in valve (2) and is drained, is stopped by pilot piston (1).
• The holding pressure of the arm cylinder bottom side exerts the right-hand force on the left side of ring-
shaped surface, whose area is equal to the area of (S2 - S1) of valve (2).
• The combined force of the right-hand force exerted on the ring-shaped surface and the spring force of the
spring (3) moves valve (2) to the right and shuts off port (A) and port (B).
PC360LC-10 10-123
Control valve
Variable back pressure valve (PC220-PQ81-042-K-00-A)
Function
• This valve creates back pressure in the drain circuit to prevent cavitation caused by negative pressure in
each actuator circuit (motors, cylinders, etc.).
• In order to reduce output loss, this valve reduces the back pressure in the drain circuit when any operation
other than the travel and swing is performed.
Operation (ALL-PQ81-044-K-01-A)
When engine is stopped

• Pressurized oil is not supplied from the main pump to self-pressure reducing valve (1).
• No oil pressure is transmitted from variable back pressure solenoid valve (3) to spring chamber (C), and
valve (6) is pressed to the right by the reaction force of spring (5).
• Drain circuit (A) of the control valve is interconnected to port (T) through orifice (b) of valve (6).
10-124 PC360LC-10
Control valve
When engine is running (during swing or travel operation)

• The pressurized oil (PR) from self-pressure reducing valve (1) flows to variable back pressure solenoid
valve (3).
• Since drive signal (IS3) of variable back pressure solenoid valve (3) is "OFF", pressurized oil (PR) is flown
to spring chamber (C) of variable back pressure valve (4).
• Pressurized oil (PR) transmitted to spring chamber (C) exerts a force on the left end face of valve (6)
(surface of fd), and it pushes valve (6) to the right as a combined force with the reaction force of spring
(5).
• Pressure (PA) of drain circuit (A) of the control valve acts on the right end face of valve (6) (surface of fd1)
to push valve (6) to the left.
• Valve (6) balances at a position where it creates back pressure (PA) determined as follows; PA = (Area of
surface fd) x Pressure (PR) + Reaction force of spring (5) / Area of surface fd1
• Accordingly, the oil flow rate from drain circuit (A) of the control valve to port (T) is limited. In other words,
the set pressure of variable back pressure valve (4) is adjusted.
PC360LC-10 10-125
Control valve
When engine is running (other than swing or travel operation)

• The pressurized oil from self-pressure reducing valve (1) flows to variable back pressure solenoid valve
(3).
• Since drive signal (IS3) of variable back pressure solenoid valve (3) is "ON", the pressurized oil (PR) from
self-pressure reducing valve (1) flown to spring chamber (C) of variable back pressure valve (4) is drained
through variable back pressure solenoid valve (3).
• Only the reaction force of spring (5) pushes valve (6) to the right.
• Pressure (PA) of drain circuit (A) of the control valve acts on the right end face of valve (6) (surface of fd1)
to push valve (6) to the left.
• Valve (6) balances at a position where it creates back pressure (PA) determined as follows; PA = Reaction
force of spring (5) / Area of surface fd1
• Accordingly, the oil flow rate from drain circuit (A) of the control valve to port (T) is limited. In other words,
the set pressure of variable back pressure valve (4) is adjusted.
10-126 PC360LC-10
Control valve
Main relief valve (PC220-PQ91-041-K-00-A)
1. Spring
2. Poppet
Function (PC220-PQ91-042-K-00-A)
• This valve has two selectable settings for its set pressure.
• If the extra power is necessary, this valve is set to the high-pressure setting when pilot pressure (P) is
applied to it from the 2-stage relief solenoid valve.
• The relief valve set pressure is determined by the load at installed length of spring (1). (1st stage set
pressure)
• When the 1st stage set pressure is set correctly, the 2nd stage set pressure does not need to be set.
Setting the 1st stage set pressure completes the setting of the 2nd stage set pressure.
Operation (PC-PQ91-044-K-00-A)
When pilot pressure (P) is shut off (low pressure setting)

• The set pressure is determined by the load at installed length of spring (1).
When pilot pressure (P) is supplied (high pressure setting)

• The load at installed length of spring (1) is added with the force exerted by pilot pressure (P) applied to the
area of diameter (d1) of poppet (2), raising the set pressure to higher level.
PC360LC-10 10-127
Control valve
2-stage suction-safety valve (PC300-PQJ2-041-K-00-A)
[To be installed to port (B) on the boom cylinder head side and port (B) of the service valve]
1. Spring
2. Piston
3. Spring
4. Holder
Function (PC220-PQJ2-042-K-00-A)
• This valve has two settings for its set pressure.
• This valve is set to the low-pressure setting when the pilot pressure is applied to it from the attachment
circuit selector solenoid valve.
• ON/OFF of the pilot pressure changes the set pressure according to the type of the installed attachment
(breaker, crusher, etc.).
• The set pressure of this valve is determined by the load at installed length of spring (1). (High-pressure
side)
• The set pressure of the low-pressure setting is determined by the travel of the piston.
10-128 PC360LC-10
Control valve
Operation (ALL-PQJ2-044-K-00-A)
When pilot pressure (P) is shut off (high pressure setting)

• Since pilot pressure (P) is shut off, piston (2) is pressed to the left by force of spring (3). [Load at installed
length of spring (1) < Load at installed length of spring (3).]
• The load at installed length of spring (1) becomes maximum, inducing high-pressure setting.
• Passage (B) is interconnected to the drain circuit via passage (C) and chamber (D).
When pilot pressure (P) is supplied (low pressure setting)

• When pilot pressure (P) is supplied, the pilot pressure is transmitted to part (A) through passage (B).
• The pilot pressure acts on the pressure receiving diameter at part (A) [(d1) – (d2)] of piston (2).
• Piston (2) compresses spring (3) by receiving pilot pressure and moves to the right until it contacts holder
(4).
• Since spring (1) is expanded and reducing its load at installed length, the set pressure is lowered.
• The amount of pressurized oil for stroke of piston (2) is drained from passage (C) via chamber (D) .
PC360LC-10 10-129
Swing motor
Swing motor (PC300-J610-041-K-00-A)
MA: From control valve (LEFT swing port)

MB: From control valve (RIGHT swing port)
B: From swing holding brake solenoid valve
S: From control valve (variable back pressure valve)
PU: 2-stage relief solenoid valve
1. Reversing prevention valve
2. 2-stage swing relief valve
10-130 PC360LC-10
Swing motor
1. Brake spring
2. Drive shaft
3. Spacer
4. Case
5. Disc
6. Plate
7. Brake piston
8. Housing
9. Piston
PC360LC-10 10-131
Swing motor
10. Cylinder block

11. Valve plate
12. Center shaft
13. Center spring
14. Check valve
15. Check valve spring
16. Shuttle valve
17. Shuttle valve spring
Specifications (PC300-J610-030-K-00-A)
Type KMF230ABE-5
Theoretical displacement (cm3/rev) 229.4
2-stage swing relief valve pressure (MPa {kg/cm2}) 27.9 {285}
2-stage swing relief oil flow Low-pressure setting 280
(l/min) High-pressure setting 100
Rated speed (rpm) 1,130
Brake releasing pressure (MPa {kg/cm2}) 1.9 ± 0.4 {19 ± 4}
Swing holding brake (PC300-J6A0-044-K-00-A)

When solenoid valve is de-energized
• As the swing holding brake is de-energized, the pressurized oil from the self-pressure reducing valve is
blocked.
• Port (B) is connected to tank circuit.
• Brake piston (7) is pushed downward by brake spring (1).
• Disc (5) and plate (6) are pushed against each other to apply the brake.
10-132 PC360LC-10
Swing motor
When solenoid valve is energized
• As the swing holding brake solenoid valve is energized, the valve is switched.
• The pressurized oil from self-pressure reducing valve enters port (B), and flows into brake chamber (a).
• After entering chamber (a), the pressurized oil compresses brake spring (1) and moves brake piston (7)
upward.
• Disc (5) is separated from plate (6), releasing the brake.
Relief valve (PC220-J6B1-041-K-00-A)

• The relief valve portion consists of check valves (2) and (3), shuttle valves (4) and (5), and relief valve (1).
Function (PC220-J6B1-044-K-00-A)
• When the swing is stopped, control valve (6) blocks the motor outlet circuit, but the motor rotation is
continued by inertial force.
• If the pressure of motor outlet circuit becomes abnormally high, it may cause damage to the motor.
• In order to prevent the motor damage, the relief valve relieves the abnormally high pressure to port (S)
from the motor outlet (high-pressure side).
PC360LC-10 10-133
Swing motor
Operation (PC300-J6B1-044-K-00-A)
When swinging is started
• When swing is started RIGHT, the pressurized oil from the pump is supplied to port (MA) through control
valve (6).
• The pressure at port (MA) rises, the starting torque is generated in the motor, and the motor starts to
rotate.
• Pressurized oil is supplied to port (PU) of the motor, increasing the set pressure of the motor.
• During swing acceleration, the pilot pressure from 2-stage swing relief solenoid valve (7) is applied to port
(PU) to restrict the relief volume.
• The pressurized oil from the outlet of the motor passes the control valve (6) through port (MB) and returns
to the tank.
10-134 PC360LC-10
Swing motor
When swing is stopped
• When the swing operation is returned to the NEUTRAL from RIGHT swing operation, the supply of
pressurized oil from the pump to port (MA) is stopped.
• The pressurized oil from the motor outlet cannot return to the tank since the return circuit to the tank is
blocked by control valve (6). Thus, pressure on port (MB) increases.
• If the pressure in port (MB) becomes too high, the pressurized oil returns to the hydraulic tank through
relief valve (1) and port (S).
• Rotation resistance is generated on the motor and hence the brake starts working.
• When the pressure at port (MB) comes to be higher than that at port (MA), shuttle valve (4) is pressed.
• The pressure in chamber (C) becomes the same as that of port (MB), and is increased to the set pressure
of relief valve (1).
• A high braking torque works on the motor, thereby stopping the motor.
• While relief valve (1) is actuated, the relieved pressurized oil and the pressurized oil from port (S) are
supplied to port (MA) through the check valve (3).
• Thus, cavitations is prevented from generating on port (MA).
PC360LC-10 10-135
Swing motor
2-stage swing relief valve (PC300-JA1A-041-K-00-A)
1. Valve seat
2. Valve
3. Piston
4. Spring
5. Spring
6. Piston
7. Rod
Function (PC300-JA1A-042-K-00-A)
• This valve has two selectable settings for set pressure.
• The set pressure of this valve is determined by the load at installed length of spring (4).
• During swing acceleration, this valve receives pilot pressure (PU) from the 2-stage swing relief solenoid
valve and decreases the relief quantity (drain quantity).
• If pressure (P) is constant, energy loss can be reduced by decreasing oil flow (Q), or relief quantity (drain
quantity), according to the formula of [Energy loss = Pressure (P) x Oil flow (Q)]. Decrease of energy loss
leads to the improvement of fuel consumption.
A: Pilot pressure blocked (low-pressure setting)

B: Pilot pressure applied (high-pressure setting)
P: 27.9 MPa {285 kg/cm2}
Q1: 260 l/min
Q2: 100 l/min
10-136 PC360LC-10
Swing motor
Operation (PC300-JA1A-044-K-00-A)
When pilot pressure (PU) is blocked (low-pressure setting)

• The set pressure is determined by the load at installed length of spring (4).
When pilot pressure (PU) is applied (high-pressure setting)

• During swing acceleration, pilot pressure (PU) from the 2-stage swing relief solenoid valve acts on the
power receiving area (d2 – d1).
• Spring (4) is compressed, the load at installed length of the spring is increased, and then the passage
between valve (2) and valve seat (1) is narrowed while the pump delivery is decreased by the controller.
As a result, the flow rate in hydraulic relief decreases when relief pressure is constant.
PC360LC-10 10-137
Swing motor
Swing motor reverse prevention valve (PC-J6B2-041-K-00-A)
MA: From control valve (left swing port)

MB: From control valve (right swing port)
10-138 PC360LC-10
Swing motor
T1: To hydraulic tank

T2: To hydraulic tank
1. Valve body
2. Spool (MA side)
3. Spring (MA side)
4. Plug (MA side)
5. Spool (MB side)
6. Spring (MB side)
7. Plug (MB side)
Explanatory drawing of effects
Function (PC220-J6B2-042-K-00-A)
• At the stop of swing operation, the upper structure may swing back. This is due to inertia of the mass of
the upper structure, the backlash and rigidity of the swing machinery system, and compressibility of the
hydraulic oil. This valve prevents such movement.
• The valve contributes to prevention of load spillage when the swing is stopped and also contributes to
reduction in the cycle time (enhances the positioning performance, enabling you to proceed to the next
work quicker than ever).
PC360LC-10 10-139
Swing motor
Operation (PC220-J6B2-044-K-00-A)
When brake pressure is generated in port (MB)
• Pressure (MB) is led to chamber (d) through notch (g).

• As (D1 > D2) holds in regards to circle areas of spool (5), spring (6) is compressed and spool (5) is moved
to the left.
• Port (MB) and chamber (e) are interconnected to each other.
• Since pressure (MA) is lower than the set pressure of spring (3), spool (2) does not move and the
pressurized oil is blocked. Thus the braking force is ensured.
When motor reversing pressure is generated in port (MA)
• The trapped pressure in port (MB) turns the motor in the opposite direction. (1st reverse rotation)
• Reversing pressure is generated in port (MA). Pressure (MA) is transmitted to chamber (a).
• As (D3 > D4) holds in regard to circle areas of spool (2), spring (3) is compressed and spool (2) is moved
to the right.
• Port (MA) and chamber (b) are interconnected to each other.
• Port (b) is interconnected to port (f) through the drilled hole (h) in spool (5). This bypasses the reversing
pressure in port (MA) to port (T), thereby preventing the 2nd reverse rotation of the motor.
10-140 PC360LC-10
Travel motor
Travel motor (PC300-C400-041-P-00-A)
L.H. travel motor

PA: From control valve (L.H. travel REVERSE port)
PB: From control valve (L.H. travel FORWARD port)
R.H. travel motor

PA: From control valve (R.H. travel FORWARD port)
PB: From control valve (R.H. travel REVERSE port)
P: From travel speed acceleration solenoid valve
B: Plug (Brake release pressure port)
MA: Port (PA) pressure pickup port
MB: Port (PB) pressure pickup port
PC360LC-10 10-141
Travel motor
1. Output shaft
2. Motor case
3. Rocker cam
4. Piston
5. Cylinder block
6. Valve plate
7. End cover
8. Slow return valve
9. Brake spring
10-142 PC360LC-10
Travel motor
10. Brake piston

11. Brake ring
12. Plate
13. Disc
14. Regulator piston
15. Suction-safety valve
16. Counterbalance valve
17. Safety valve
18. Ball
19. Regulator valve
20. Spring
21. Spool return spring
22. Check valve spring
23. Regulator piston spring
24. Regulator piston spring
25. Regulator valve spring
26. Counterbalance spool
Specifications (PC300-C400-030-P-00-A)
Model HMV180ADT-2
Min. 106.7
Theoretical displacement (cm3/rev)
Max. 182.4
Rated pressure: MPa {kg/cm2} 37.3 {380}
At minimum volume 2,460
Rated speed (rpm)
At maximum volume 1,140
Brake releasing pressure (MPa {kg/cm2}) 1.18 {12}
Travel speed selector pressure (MPa {kg/cm2}) 0.78 {8.0}
PC360LC-10 10-143
Travel motor
Operation of motor (PC300-C400-044-K-00-A)

At low-speed travel setting (motor swash plate angle is at maximum)
• When the solenoid valve is de-energized, the pressurized pilot oil from the self-pressure reducing valve
does not flow to port (P).
• Regulator valve (19) is pushed to the right by spring (25).
• Pressurized oil being conducted from the control valve to end cover (7) by pressing slow return valve (8) is
shut off by regulator valve (19).
• The fulcrum (a) of rocker cam (3) is located eccentrically to the point of action (b) for the resultant force of
piston thrusts of cylinder block (5).
• The resultant force of piston thrusts acts on rocker cam (3) as a moment that tilts the rocker cam toward
the maximum swash plate angle position.
• The pressurized oil in regulator piston (14) flows through orifice (c) in regulator valve (19), and is drained
into the motor case.
• Rocker cam (3) tilts toward the maximum swash plate angle position, thus, the motor capacity is
maximized and the travel speed comes to low.
10-144 PC360LC-10
Travel motor
At high-speed travel setting (motor swash plate angle is at minimum)
• When the solenoid valve is energized, the pressurized pilot oil from the self-pressure reducing valve flows
to port (P).
• Regulator valve (19) is pressed to the left.
• The pressurized oil from the control valve flows through passage (d) of regulator valve (19), and enters
regulator piston (14).
• Regulator piston (14) is pressed to the right.
• Rocker cam (3) tilts toward the minimum swash plate angle position. The motor capacity is minimized and
the travel speed is comes to high.
PC360LC-10 10-145
Travel motor
Operation of parking brake (PC300-C4A0-044-K-00-A)

When starting traveling
• When the travel lever is operated, the pressurized oil from the pump acts on counterbalance valve spool
(26) to make the parking brake circuit.
• The pressurized oil flows in chamber (a) of brake piston (10) and compresses spring (9), pushing piston
(10) toward right.
• Since the force pressing plate (12) and disc (13) against each other is eliminated, they are separated and
the brake is released.
10-146 PC360LC-10
Travel motor
When stopping traveling
• When the travel lever is returned to NEUTRAL, counterbalance valve spool (26) returns to the neutral
position, and the parking brake circuit is blocked.
• The pressurized oil in chamber (a) of brake piston (10) is drained to the case through orifice (f) of brake
piston (10).
• Brake piston (10) is pressed to the right by spring (9).
• Plate (12) and disc (13) are pressed against each other, and the brake is applied.
• When brake piston (10) is returned, the flow of pressurized oil is restricted by slow return valve (8).
• The time retard to apply is set and the brake is applied after the machine stops.
PC360LC-10 10-147
Travel motor
Brake valve (PC300-C4Q0-041-K-00-A)
• Brake valve consists of suction safety valve (15), counterbalance valve (16), and safety valve (17).
Counterbalance valve (PC300-C4N0-042-K-00-A)
Function
• When the machine travels down a slope, its travel speed tends to get faster than the motor (engine) speed
because of the downward force generated by its own weight.
• If the machine travels with the engine at low speed, the motor may run idle, and the machine runs out of
control, causing a very dangerous situation.
• These valves serve to prevent the above problem by enabling the machine to travel at a speed that
matches the engine speed (pump delivery).
10-148 PC360LC-10
Travel motor
Operation (PC300-C4N0-044-K-00-A)
Operation when pressurized oil is supplied
• If the travel lever is operated, the pressurized oil is supplied from the control valve to port (PA).
• The oil opens suction safety valve (15A), and then flows from motor inlet port (MA) to motor outlet port
(MB).
• Since the motor outlet circuit is blocked by suction safety valve (15B) and spool (26), the pressure of the
supply side circuit increases.
PC360LC-10 10-149
Travel motor
• The pressurized oil of the supply side circuit flows through orifices (E1) and (E2) of spool (26) to chamber
(S1).
• When the pressure in chamber (S1) becomes higher than the spool selector pressure (reaction force of
spring (21)), spool (26) is pushed to the right.
• Both motor outlet port (MB) and port (PB) are connected to outlet passage (B1). As the result, the motor
outlet side opens and the motor rotates.
10-150 PC360LC-10
Travel motor
Brake operation at travelling downhill
• When the machine almost runs out of control during downhill travel, the motor runs idle and the pressure
of the inlet side circuit decreases.
• The pressure in chamber (S1) decreases, as the oil is drained through orifices (E1) and (E2).
• When the pressure in chamber (S1) becomes lower than the spool selector pressure, spool (26) is
returned to the left by the reaction force of spring (21) and outlet passage (B1) is throttled.
• The pressure of the motor outlet side circuit increases and rotational resistance is generated in the motor,
preventing the machine from running out of control.
• Spool (26) moves to a position where the total of the force by the machine itself and the pressure at the
motor inlet port balance with the pressure in the motor outlet port.
• Narrowing down the motor outlet side circuit allows the machine to travel at a speed that matches the
pump delivery.
Suction safety valve (PC300-C660-042-K-00-A)
Function
• As long as the machine is stopped (or it travels down a slope), the counterbalance valve blocks the inlet
and outlet circuits of the motor.
• Since the motor is rotated by inertial force, the pressure in the motor outlet port is abnormally increased,
the motor and piping may be damaged.
• The safety valve releases this abnormal pressure to the inlet port of the motor in order to prevent damages
to the equipment.
PC360LC-10 10-151
Travel motor
Operation (PC300-C660-044-K-00-A)
Bidirectional operation
(1) When pressure in chamber (MB) becomes high (when rotating clockwise)
• As long as the machine travel is stopped (or it is travelling downhill), the check valve of counterbalance
valve closes chamber (MB) of the outlet port circuit.
• As motor tends to keep rotating by inertial force, the pressure at outlet (MB) increases.
• When the pressure exceeds the set pressure, the force [difference of circle area between (D1) and (D2) x
pressure] compresses spring (2).
• Poppet (1) is moved to the left, and pressurized oil flows to chamber (MA) of the opposite side circuit.
10-152 PC360LC-10
Travel motor
(2) When pressure in chamber (MA) becomes high (when rotating counterclockwise)
• As long as the machine travel is stopped (or it is travelling downhill), the check valve of counterbalance
valve closes chamber (MA) of the outlet port circuit.
• As the motor tends to keep rotating by inertial force, the pressure at outlet (MA) increases.
• When the pressure exceeds the set pressure, the force [difference of circle area between (D1) and (D3) x
pressure] compresses spring (2).
• Poppet (1) is moved to the left, and pressurized oil flows to chamber (MB) of opposite side circuit.
PC360LC-10 10-153
Travel motor
Operation of mechanism for varying set pressure
(1) When starting travel (high-pressure setting)

• When the travel lever is operated, the pressurized oil from the pump moves spool (4) to the right.
• The pilot circuit to the safety valve is opened, and the pressurized oil flows to chamber (G) through
chamber (H) and passage (J).
• Piston (3) is pushed rightward, spring (2) is compressed and the set load is increased.
• The set pressure of the safety valve changes to high-pressure setting, providing a large tractional force.
10-154 PC360LC-10
Travel motor
(2) When travel is stopped (low-pressure setting)

• When the travel lever is set to the neutral, the pressure in chamber (PA) drops and spool (4) returns to the
neutral position.
• Until spool (4) returns to the neutral position, the pressurized oil in chamber (J) keeps on flowing through
passage (H) and chamber (G) to chamber (PA).
• Piston (3) moves to the left side, decreasing the set load.
• The set pressure of the safety valve changes to low-pressure setting, reducing shocks when the travel
speed is reduced.
Set pressure of safety valve

High-pressure setting: 40.2 MPa {410 kg/cm2}
(At starting and in traveling)
Low-pressure setting: 27.5 MPa {280 kg/cm2} (when stopped)
PC360LC-10 10-155
PPC valve
PPC valve (ALL-CW10-001-P-00-A)

Work equipment and swing PPC valve (PC-PL28-041-K-00-A)
a PPC: Abbreviation for Proportional Pressure Control
10-156 PC360LC-10
PPC valve
L.H. work equipment control lever

P1: To control valve (arm OUT port)
P2: To control valve (arm IN port)
P3: To control valve (LEFT swing port)
P4: To control valve (RIGHT swing port)
R.H. work equipment control lever

P1: To control valve (boom LOWER port)
P2: To control valve (boom RAISE port)
P3: To control valve (bucket CURL port)
P4: To control valve (bucket DUMP port)
T: To hydraulic oil tank
PC360LC-10 10-157
PPC valve
10-158 PC360LC-10
PPC valve
1. Spool
2. Piston
3. Disc
4. Nut (for lever connection)
5. Joint
6. Plate
7. Retainer
8. Valve body
9. Filter
Operation (PC-PL28-044-K-00-A)
When control lever is in NEUTRAL position

• Ports (A) and (B) of the control valve and ports (P1) and (P2) of the PPC valve are connected to drain
chamber (D) through fine control hole (f) in spool (1).
PC360LC-10 10-159
PPC valve
When control lever is in fine control range
(When moved from NEUTRAL to fine control range)

• When piston (4) is pushed by disc (5), retainer (9) is pushed and spool (1) is also pushed by metering
spring (2) and moves downward.
• When fine control hole (f) is disconnected from drain chamber (D), it is connected to pump pressure
chamber (PP) at almost the same time.
• The pilot pressure from the main pump is transmitted from port (P1) to port (A) through the fine control
hole (f).
• When the pressure in port (P1) becomes higher, spool (1) is pushed back and fine control hole (f) is
disconnected from pump pressure chamber (PP). At almost the same time, it is connected to drain
chamber (D) to release the pressure in port (P1).
• Accordingly, spool (1) moves up and down until the force of metering spring (2) is balanced with the force
exerted by the pressure in port (P1).
• The positional relationship between spool (1) and valve body (10) [fine control hole (f) is located between
drain chamber (D) and pump pressure chamber (PP)] does not change until retainer (9) comes in contact
with spool (1).
• Metering spring (2) is compressed in proportion to the control lever travel.
• In addition, the pressure in port (P1) increases in proportion to the control lever travel.
• Accordingly, the control valve spool moves to a position at which the pressure in port (A) [equal to the
pressure in port (P1)] is balanced with the reaction force of the control valve spool return spring.
10-160 PC360LC-10
PPC valve
(When returned to fine control range)

• When disc (5) begins to return, spool (1) is pushed up by the force of centering spring (3) and the force
exerted by the pressure in port (P1).
• Fine control hole (f) is connected to drain chamber (D), and the pressurized oil in port (P1) is released.
• If the pressure in port (P1) is excessively reduced, spool (1) is depressed by metering spring (2).
• Fine control hole (f) is disconnected from drain chamber (D), and at almost the same time, it is connected
to pump pressure chamber (PP).
• The pump pressure is supplied until the pressure at port (P1) recovers to the level corresponding to the
lever position.
• When the spool of the control valve returns, the pressurized oil in drain chamber (D) flows in through fine
control hole (f') in the valve on the side that is not operated. The oil passes through port (P2) and flows into
port (B) to replenish the port with pressurized oil.
PC360LC-10 10-161
PPC valve
When control lever is moved to stroke end

• Disc (5) depresses piston (4), and retainer (9) depresses spool (1).
• Fine control hole (f) is disconnected from drain chamber (D), and it is connected to pump pressure
chamber (PP).
• The pilot pressure oil from the self-pressure reducing valve passes through fine control hole (f) and flows
from port (P1) to port (A) and pushes the control valve spool.
• The oil returning from port (B) flows from port (P2) into drain chamber (D) through fine control hole (f').
10-162 PC360LC-10
PPC valve
Travel PPC valve (PC-C6V0-041-K-00-A)

P1: To control valve (L.H. travel REVERSE port)
P2: To control valve (L.H. travel FORWARD port)
P3: To control valve (R.H. travel REVERSE port)
P4: To control valve (R.H. travel FORWARD port)
PC360LC-10 10-163
PPC valve
1. Plate
2. Case
3. Piston
4. Seal
5. Spool
6. Damper
10-164 PC360LC-10
PPC valve
Operation (PC300-C6V0-044-K-00-A)
AT NEUTRAL
• Ports (A) and (B) of the control valve and ports (P1) and (P2) of the PPC valve are connected to drain
chamber (D) through fine control hole (f) in spool (1).
PC360LC-10 10-165
PPC valve
(fine control from neutral)

• When piston (4) is pushed by lever (5), retainer (9) is pushed and spool (1) is also pushed by metering
spring (2) and moves downwards.
• When fine control hole (f) is disconnected from drain chamber (D), it is connected to pump pressure
chamber (PP) at almost the same time.
• The pilot pressure oil from the control pump is routed from port (P1) through fine control hole (f) to port (A).
• When the pressure in port (P1) becomes higher, spool (1) is pushed back and fine control hole (f) is
disconnected from pump pressure chamber (PP). At almost the same time, it is connected to drain
chamber (D) to release the pressure in port (P1).
• Spool (1) moves up and down until the force of metering spring (2) is balanced with the force exerted by
the pressure in port (P1).
• The positional relationship between spool (1) and valve body (10) [where fine control hole (f) is between
drain chamber (D) and pump pressure chamber (PP)] does not change until retainer (9) comes in contact
with spool (1).
• Metering spring (2) is compressed in proportion to the control lever travel.
• In addition, the pressure in port (P1) increases in proportion to the control lever travel.
• The control valve spool moves to a position at which the pressure in port (A) [equal to the pressure in port
(P1)] is balanced with the reaction force of the control valve spool return spring.
10-166 PC360LC-10
PPC valve
(When returning control lever)

• When lever (5) starts to be returned, spool (1) is pushed up by the force of centering spring (3) and the
force exerted by the pressure at port (P1).
• Fine control hole (f) is connected to drain chamber (D), and the pressurized oil in port (P1) is released.
• If the pressure in port (P1) is excessively reduced, spool (1) is pushed down by metering spring (2).
• Fine control hole (f) is disconnected from drain chamber (D), and at almost the same time, it is connected
to pump pressure chamber (PP).
• The pump pressure is provided until the pressure at port (P1) is recovered to the extent that the pressure
is equal to a pressure for the lever position.
• When the spool of the control valve returns, the pressurized oil in drain chamber (D) flows in through fine
control hole (f') in the valve on the side that is not operated. The oil passes through port (P2) and flows into
port (B) to replenish the port with pressurized oil.
PC360LC-10 10-167
PPC valve
When lever is operated to travel end

• Lever (5) pushes down piston (4), and retainer (9) pushes down spool (1).
• Fine control hole (f) is disconnected from drain chamber (D), and it is connected to pump pressure
chamber (PP).
• The pilot pressure oil from the self-pressure reducing valve passes through fine control hole (f) and flows
from port (P1) to port (A) and pushes the control valve spool.
• The oil returning from port (B) flows from port (P2) into drain chamber (D) through fine control hole (f').
10-168 PC360LC-10
PPC valve
1st-line attachment PPC valve (with EPC valve) (PC-PL29-041-K-00-A)
(if equipped)
a For details of operation, see "Work equipment and swing PPC valve".

P1: To control valve (service valve 1 port)
PC360LC-10 10-169
PPC valve
1. Spool
2. Piston
3. Lever
4. Plate
5. Retainer
6. Block
7. Valve body
8. EPC valve
EPC valve (PC-PL2B-041-K-00-A)

(if equipped)

C: To PPC valve (R.H. attachment)
10-170 PC360LC-10
PPC valve
1. Valve body
2. Plug
3. Spool
4. Push pin
5. Coil
6. Plunger
7. Connector
Function (PC-PL2B-042-K-00-A)
• The EPC valve consists of the proportional solenoid portion and the hydraulic valve.
• When a signal current (i) from the pump controller is received, the EPC output pressure proportional to the
amperage of current is generated and output to the control valve.
PC360LC-10 10-171
PPC valve
Operation (PC-PL2B-044-K-00-A)
When signal current is zero amp. (coil is de-energized)

• Since the signal current from the controller does not flow through coil (5), coil (5) is de-energized.
• Spool (2) is pushed to the right by spring (3).
• Port (P) is blocked, so the pressurized oil from the front pump does not flow to the control valve.
• The pressurized oil from the control valve is drained to the tank through port (C) and port (T).
10-172 PC360LC-10
PPC valve
When signal current is minute (coil is energized)

• When minute signal current flows through coil (5), coil (5) is energized and the thrust pushing plunger (6)
leftward is generated.
• Push pin (4) pushes spool (2) to the left, and the pressurized oil from port (P) flows to port (C).
• The pressure in port (C) increases and the combined force of the force applied on surface (a) of spool (2)
and the reaction force of spring (3) become larger than the thrust of plunger (6).
• Spool (2) is pressed to the right, so port (P) is disconnected from port (C) and port (C) is connected to port
(T).
• Spool (2) moves to a position where the thrust of plunger (6) is equal to the total of the force exerted by the
pressure in port (C) and the force of spring (3).
• Thus, the circuit pressure between the EPC valve and the control valve is controlled in proportion to the
amperage of the signal current.
PC360LC-10 10-173
PPC valve
When signal current is maximum (coil is energized)

• Coil (5) is energized when the signal current flows through coil (5).
• As the signal current is the maximum, the thrust of plunger (6) is also maximized.
• Spool (2) is pushed to the left by push pin (4).
• The pressurized oil flows from port (P) to port (C) at the maximum rate, and the circuit pressure between
the EPC valve and control valve is maximized.
• Port (T) is blocked, so no pressurized oil flows to the hydraulic tank.
10-174 PC360LC-10
PPC valve
2nd-line attachment PPC valve (PC-PL2A-041-K-00-A)
(if equipped)
a For details of operation, see "Work equipment and Swing PPC valve".

PC360LC-10 10-175
PPC valve
1. Spool
2. Piston
3. Lever
4. Plate
5. Retainer
6. Valve body
10-176 PC360LC-10
Solenoid valve
Solenoid valve (PC300-PQPT-041-K-00-A)
For PPC lock, swing motor 2-stage relief, travel junction, travel speed, swing brake, machine push-up, and 2-
stage relief
1. PPC lock solenoid valve

2. Swing motor 2-stage relief solenoid valve
3. Travel junction solenoid valve
5. Swing brake solenoid valve
6. Machine push-up solenoid valve
7. 2-stage relief solenoid valve
T: To tank
A1: To PPC valve
A2: To swing motor 2-stage relief valve
A3: To main valve (travel junction valve)
A4: To L.H. and R.H. travel motors
A5: To swing motor
A6: To main valve (2-stage safety valve at boom cylinder head
A8: To main valve (2-stage relief valve)
P1: From main pump
ACC: To accumulator
PC360LC-10 10-177
Solenoid valve
10-178 PC360LC-10
Solenoid valve
1. Connector
2. Moving core
3. Coil
4. Spool
5. Block
6. Spring
Operation (ALL-PQPT-044-K-00-A)
Operation of check valve
• This valve is installed between port (P) and the PPC solenoid valve. When the engine is stopped, plunger
(1) is pushed back to the left by the reaction force of spring (2), so the passage between ports (ACC) and
(P) is blocked, keeping the pressure in the accumulator.
• When the engine is running, plunger (1) is pushed to the right with the pilot pressure that is sent to port (P),
so port (P) is connected to port (ACC).
PC360LC-10 10-179
Solenoid valve
Operation of solenoid valve
When solenoid valve is "de-energized" (circuit is blocked)
• Coil (1) is de-energized when no signal current flows through coil (1).
• Spool (2) is pushed back to the left by reaction force of spring (3).
• As the passage between ports (P) and (A) is blocked, the pilot pressure is not fed to the actuator through
port (A). At the same time, the passage to port (T) is made, so the oil from the actuator is drained to the
hydraulic tank.
When solenoid valve is "energized" (circuit is made)
• Coil (1) is energized when the signal current flows through coil (1).
• Spool (2) is pushed to the right by push pin (4).
• The passage between ports (P) and (A) is made, so the pilot pressure flows to the actuator through port
(A). At the same time, the passage to port (T) is blocked, so the oil from the actuator does not flow to the
hydraulic tank.
10-180 PC360LC-10
Attachment circuit selector valve
Attachment circuit selector valve (PC300-PQJ3-041-K-00-A)
(if equipped)
PI: From attachment selector solenoid valve

V: To port of control valve for attachment 1
ACC: To accumulator
ATT: To attachment
TS: To hydraulic tank
1. Spool
Function (PC220-PQJ3-042-K-00-A)
• For a machine equipped with a breaker, this valve serves to interconnect between the main circuit from the
control valve to the breaker and the accumulator.
• For a machine equipped with other attachment (crusher, etc.), this valve serves to disconnect the main
circuit from the accumulator.
PC360LC-10 10-181
Operation (PC-PQJ3-044-K-00-A)
When attachment other than breaker is installed
• Spool (1) is pressed to the left by the force of spring (2).

• Port (ATT) is interconnected to port (V) and is disconnected from port (T). Thus, the attachment is
interconnected to the control valve.
10-182 PC360LC-10
When breaker is installed
• Pilot pressure (PI) from the attachment circuit selector solenoid valve compresses spring (2), and spool (1)
moves to the right to its stroke end.
• Port (ATT) is disconnected from port (V) and is interconnected to port (T).
• The pressurized oil returning from the breaker returns directly to the hydraulic tank via port (T) without
passing through the control valve.
PC360LC-10 10-183
Center swivel joint
Center swivel joint (PC300-J8E0-041-K-00-A)
A1: To L.H. reverse travel motor [Port (PB)]

A2: From control valve [port (A2)]
B1: To L.H. forward travel motor [Port (PA)]
B2: From control valve [port (B2)]
C1: To R.H. reverse travel motor [Port (PA)]
C2: From control valve [port (A5)]
D1: To R.H. forward travel motor [Port (PB)]
D2: From control valve [port (B5)]
E1: To R.H. and L.H. travel motors [port (Pi)]
E2: From travel speed acceleration valve
DR1: From R.H. and L.H. travel motors [port (T)]
DR2: To hydraulic tank
1. Cover
10-184 PC360LC-10
Center swivel joint
2. Rotor
3. Slipper seal
4. O-ring
5. Shaft
PC360LC-10 10-185
Accumulator
Accumulator (PC-PL40-001-K-00-A)
PPC accumulator (PC-PL40-041-K-00-A)
1. Gas plug
2. Shell
3. Poppet
4. Holder
5. Bladder
6. Oil port
Specifications (PC-PL40-030-K-00-A)
Gas to be used Nitrogen gas

Volume of gas (cc) 300
Charged pressure 1.18 {12}
(MPa {kg/cm2}) (at 80°C)
Max. operating pressure
6.86 {70}
(MPa {kg/cm2})
Function (PC-PL40-042-K-01-A)
• This accumulator is installed to the solenoid valve. Even if the engine is stopped while the work equipment
is raised, pilot oil pressure can be supplied to the work equipment control valve with the pressure of the
compressed nitrogen gas in the accumulator to operate the spool and lower the work equipment by its
own weight.
10-186 PC360LC-10
Work equipment
Work equipment (ALL-L000-001-K-00-A)
Work equipment (PC-L410-041-K-00-A)
1. Bucket
2. Bucket link
3. Bucket cylinder
4. Arm
5. Arm cylinder
6. Boom
7. Boom cylinder
PC360LC-10 10-187
Work equipment
Work equipment shims (PC300-L413-040-K-00-A)

Outline
• There are two types of the work equipment shims; one is the steel shims and the other is the plastic shims.
• The work equipment shims are inserted so that the clearance in each joint of the work equipment comes
to the standard value.
Function
Steel shims
• The steel shims are primarily inserted in the parts that need to be greased every 100 hours.
• One purpose of the steel shims is to reduce the play of the work equipment in the lateral direction.
a The shims need to be inserted on only the right or left side and do not need to be inserted on the
adjustment side, depending on the quantity of the clearance to be adjusted.
Plastic shims
• The plastic shims are primarily inserted in the parts that need to be greased every 250 hours.
• The purposes of the plastic shims to be used are to reduce the play of the work equipment in the lateral
direction and prevent squeaks and scuffing caused by rubbing of the steel parts at the end faces of the
joint portions.
• Combined with the greasing interval extension bushings, the plastic shims prevent squeaks caused by
lack of grease and extend the greasing intervals.
• The plastic shims are inserted in every contact face of each part so that the steel parts at the end faces of
the joint portion do not come in contact with each other.
a Combined with the greasing interval extension bushings and dust seals, the plastic shims extend the
greasing interval to 250 hours.
10-188 PC360LC-10
Work equipment
Bucket play adjustment shim (PC300-LBKB-040-K-00-A)

Outline
• The separated iron shims are used for the connection of arm and bucket.
• By adjusting the number of shims, play at connecting part can be adjusted.
a Play can be reduced with a mechanism by deleting some shims when the play becomes large.
PC360LC-10 10-189
Cab mount and cab tipping stopper
Cab and its attachments (ALL-K000-001-K-00-A)
Cab mount and cab tipping stopper (PC300-K138-041-K-00-A)
1. Front damper
2. Rear damper
3. Cab tipping stopper
Structure
• 4 dampers are located in front and rear of cab (2 each), and fix cab and floor frame onto revolving frame.
• Oil-filled damper is used to absorb vibration.
• Cab tipping stopper (3) installed at a place in the rear section aims to secure the cab when the machine
tips over.
• As shown in following table, various dampers are available upon its mounting location.
Color of identifying seal
Location of damper Bent of craw
(printing)
Front left Yes Red (205)
Front right Yes Red (205)
Rear left None Green (270)
Rear right None Green (270)
10-190 PC360LC-10
ROPS cab
ROPS cab (PC-K000-041-K-00-A)
ROPS: Abbreviation for Roll-Over Protective Structure
1. Front window
2. Windshield wiper
3. Head lamp
4. Ceiling window
5. KOMTRAX communication antenna
6. KOMTRAX GPS antenna
7. Radio antenna
8. Door
9. Mirror
Function (PC220-K000-042-K-00-A)
• ROPS cab is a structure which protects the operator fastening a seat belt not to be crushed when the
machine tips over.
PC360LC-10 10-191
Electrical control system
Electrical system (ALL-RA1D-001-K-01-A)
Electrical control system (PC220-C050-001-K-00-A)
General system drawing (PC300-C050-051-K-00-A)
a Items marked with "*1" in drawing may or may not be installed.
10-192 PC360LC-10
PC360LC-10 10-193
10-194 PC360LC-10
Engine control function (PC220-AK60-042-K-00-A)
1. Battery disconnect switch

2. Battery
3. Battery relay
4. Fusible link
5. Fuse box
6. Starting switch
7. Engine shutdown secondary switch
9. Lock lever
10. PPC lock switch
11. Starting motor cut-off relay (for PPC lock)
12. Starting motor cut-off relay (for personal code)
13. Fuel control dial
14. Safety relay
15. Starting motor
16. Fuel supply pump
17. Sensors
18. Machine monitor
19. KOMTRAX terminal
20. Pump controller
Function
• The neutral safety circuit is employed to secure safety when the engine is started.
a The engine does not start until the lock lever is set to the "LOCK" position.
• The KOMTRAX engine cut circuit is employed to disable the engine from starting when the KOMTRAX
terminal receives an engine cut command issued through external operation.
• When you cannot stop the engine due to stuck starting switch (6), engine shutdown secondary switch (7)
is usable for stopping the engine.
Starting the engine

• If starting switch (6) is turned to "ON" position , engine controller (8) sends command current to fuel supply
pump (16).
PC360LC-10 10-195
For this reason, a fail-safe mechanism is provided with the electrical system to stop the engine when an
electrical failure occurs.
• If starting switch (6) is turned to "START" position when lock lever (9) is in the "LOCK" position, starting
current is supplied to starting motor (15) and the engine starts.
If lock lever (9) is in the "FREE" position, starting motor cut-off relay (11) cuts off the starting current to
starting motor (15), thus the engine does not start. This is the neutral safety mechanism.
• Upon receipt of the engine cut-off command from the external source, KOMTRAX terminal (19) sends the
signal to machine monitor (18).
Machine monitor (18) causes starting motor cut-off relay (12) to cut off the starting current to starting motor
(15), therefore the engine does not start.
Engine speed control

• Upon receipt of the throttle signals from fuel control dial (13) and pump controller (20), engine controller (8)
selects lower throttle signal, and sends command current to fuel supply pump (16).
Fuel supply pump (16) adjusts the fuel injection rate to control the engine speed.
Engine stop
• If starting switch (6) is turned to "OFF" position, the current from ACC terminal of starting switch (6) to
engine controller (8) is cut off, and consequently the command current to fuel supply pump (16) is cut off.
Fuel supply pump (16) stops fuel feed, decreasing the engine speed until the engine stops.
Stopping the engine with engine shutdown secondary switch

• If engine shutdown secondary switch (7) is turned to "Stop Engine" position, the current from ACC
terminal of starting switch (6) to engine controller (8) is forcibly cut off.
Above induces the same state as when starting switch (6) is turned to "OFF" position, stopping the engine.
10-196 PC360LC-10
Engine and pump combined control function (PC300-C3W0-042-K-00-A)

2. Battery
3. Battery relay
4. Fusible link
5. Fuse box
6. Resistor for PC-EPC valve
7. Pump controller
9. Machine monitor
10. Emergency pump drive switch
12. Supply pump
13. Sensor
14. Front pump swash plate sensor
15. Rear pump swash plate sensor
16. One-touch power maximizing switch
17. Front pump oil pressure sensor
18. Rear pump oil pressure sensor
PC360LC-10 10-197
19. Oil pressure sensor

20. Oil pressure switch
21. Front pump
21a. Servo
21b. LS valve
21c. PC valve
22. Rear pump
22a. Servo
22b. LS valve
22c. PC valve
23. Control valve
23a. Self-pressure reducing valve
23b. Merge-divider valve
23c.Travel junction valve
26. LS-EPC valve
Input/Output signal
a. Front pump PC-EPC valve drive signal
b. Rear pump PC-EPC valve drive signal
c. Solenoid valve GND
d. CAN signal
e. LS-EPC valve drive signal
f. Swash plate sensor signal
g. Oil pressure sensor signal
h. One-touch power maximizing switch signal
i. Oil pressure switch signal
j. 1st throttle signal
k. Supply pump control signal
l. Sensor signals
Function
• This function allows the operator to select any of the six working modes of P, E, L, ATT/P, ATT/E and B
with the working mode selector switch of the machine monitor. The most suitable combination of engine
torque (T) and pump absorption torque can be selected depending on the work of the machine. If there is
no attachment in the default setting of the service mode, the three modes of P, E and L can be set.
• The pump controller calculates the pump absorption upper limit torque based on the working mode, speed
setting by the fuel control dial, and actual engine speed, and controls the pump to maintain it near the
matching point set for each mode even at high loads.
• When the engine speed lowers, the controller prevents the engine from stopping by reducing the pump
absorption torque.
10-198 PC360LC-10
Control method in each mode

P, E, ATT/P and ATT/E modes
Matching point
Working mode Matching point
P and ATT/P (during work) 174 kW/1,800 rpm {233 HP/1,800 rpm}
E and ATT/E (during work) 144 kW/1,800 rpm {193 HP/1,800 rpm}
• In P, E, ATT/P and ATT/E modes, the engine speed is always controlled so that it is kept around the
matching point specified for each mode.
• At light loads, the engine operates at high speeds. As the load increases, the engine speed decreases
while the torque is increased, until the matching point with pump absorption torque upper limit (PT) is
reached. [See (1) in graph]
• As the load increases further, the engine speed decreases further. [See (2) in graph]
• The controller lowers the pump absorption upper limit torque (PT) to reduce the load on the engine. [See
(3) in graph]
• As the engine load decreases, the engine speed increases. [See (4) in graph]
• The controller raises the pump absorption upper limit torque (PT) to maintain it near the matching point.
[See (5) in graph]
PC360LC-10 10-199
• To save fuel consumption, the controller controls the engine to lower the engine matching speed (Nm) at
low loads (low delivery and torque). [See (6) in graph]
B and L modes
Working mode Partial output
B 78%
L 64%
Matching point
Working mode Matching point
B 136 kW/1,825 rpm {182 HP/1,825 rpm}
L 110 kW/1,500 rpm {148 HP/1,500 rpm}
• In B or L mode, the engine horsepower is controlled to a constant level.
• The controller controls the pump absorption upper limit torque (PT) to keep the engine torque constant
along the equal engine horsepower curve.
10-200 PC360LC-10
Control function during travel

• Traveling the machine in E, ATT/E or B mode leaves the working mode unchanged, but raises the pump
absorption torque and engine speed (N) to the same values as those in P mode.
• When traveling in L mode, the work mode and engine speed (N) remains unchanged, while the pump
absorption torque rises.
PC360LC-10 10-201
Control function at the time when emergency pump drive switch is turned on.
• If the controller fails and no work is possible to be done because the main pump does not work properly,
operating emergency pump drive switch (1) temporarily enables to maintain functions of the machine with
absorption torques corresponding to those in the E mode.
In this case, a constant current flows from the battery to the PC-EPC valve, so the oil pressure sensing by
the PC-EPC valve only is available.
a: Emergency (in failed condition)
b:Normal
a Emergency pump drive switch (1) is an alternative type. If the machine is operated at Emergency (a)
position when the machine is normal condition, action level L03 is shown on the display.
10-202 PC360LC-10
Pump and valve control function (PC300-C3W1-042-K-00-A)

2. Battery
3. Battery relay
4. Fusible link
5. Fuse box
7. Pump controller
9. Machine monitor
12. Supply pump
13. Sensors
14. Front pump swash plate sensor
15. Rear pump swash plate sensor
16. Front pump
16a. Servo
16b. LS valve
PC360LC-10 10-203
16c. PC valve
17. Rear pump
17a. Servo
17b. LS valve
17c. PC valve
18. Control valve
18c. Travel junction valve
18d. Main relief valve
18e. Variable back pressure valve
21. LS-EPC valve
22. Merge-divider EPC valve (for main spool)
23. Merge-divider EPC valve (for LS spool)
26. Variable back pressure solenoid valve
Input/Output signal
d. CAN signal
e. LS-EPC valve drive signal
f. Swash plate sensor signal
g. Merge-divider EPC valve (for main spool) drive signal
h. Merge-divider EPC valve (for LS spool) drive signal
i. Travel junction solenoid valve drive signal
j. 2-stage relief solenoid valve drive signal
k. Variable back pressure solenoid valve drive signal
l. 1st throttle signal
m. Supply pump control signal
n. Sensor signals
Function
• The LS control function, cut-off function, 2-stage relief function and variable back pressure function enable
the machine to have the optimum matching under various working conditions.
LS control function
• According to the actuator operation, the output pressure from the LS-EPC valve to LS valve varies and the
selector point for pump delivery amount [LS set differential pressure (DLS)] in the LS valve changes.
• The build-up time of pump delivery amount is optimized, and the ease of combined operation and fine
control is improved.
10-204 PC360LC-10
A: 0 MPa {0 kg/cm2}
B: EPC pressure (Psig) = 2.5 MPa {25 kg/cm2}
Cut-off function
• PC-EPC current (J) is increased and the flow at relief is decreased to improve fuel consumption.
Conditions for cut-off function to operate
When the one-touch power maximizing function is not activated and the average of front pump and rear
pump oil pressure sensor values is 31.1 MPa {317 kg/cm2} or higher.
The cut-off function does not work, however, while the machine is travelling in P mode and swing lock switch
is in the ON position.
A: PC-EPC current at cutoff

2-stage relief function
• If the operating conditions of 2-stage relief function are met, relief pressure during work increases.
Operating conditions for 2-stage relief function Relief pressure
• When traveling
• Swing lock switch is ON. 34.8 MPa {355 kg/cm2}
• At boom LOWER operation O
• When one-touch power maximizing function is in operation 37.2 MPa {380 kg/cm2}
• When L mode is selected
Variable back pressure function

• Set pressure of the back pressure valve varies depending on the operating conditions of the machine.
Operating conditions Setting of back pressure valve
When swinging and travelling High-pressure setting
When operating other than swinging or travelling Low-pressure setting
PC360LC-10 10-205
One-touch power maximizing function (PC300-PT23-042-K-00-A)

2. Battery
3. Battery relay
4. Fusible link
5. Fuse box
7. Pump controller
9. Machine monitor
12. Supply pump
13. Sensors
17. Front pump
17a. Servo
17b. LS valve
17c. PC valve
18. Rear pump
18a. Servo
18b. LS valve
18c. PC valve
10-206 PC360LC-10
19. Control valve

Input/Output signal
d. CAN signal
e. 2-stage relief solenoid valve drive signal
f. Pump oil pressure sensor signal
g. One-touch power maximizing switch signal
h. 1st throttle signal
i. Supply pump control signal
j. Sensor signals
Function
• By operating the one-touch power maximizing switch on the L.H. work equipment control lever knob, the
power is maximized for a limited time.
• This can be used when extra digging force is needed for a while, for example, when digging out a rock
during excavating work.
• If the one-touch power maximizing switch is pressed in P mode, E mode, ATT/P mode or ATT/E mode
when the load pressure is high, the hydraulic force will be increased by approximately 7% to boost the
digging force.
• The functions are automatically set as follows.
Function Setting
34.8 MPa {355 kg/cm2}
2-stage relief function O
37.2 MPa {380 kg/cm2}
Cut-off function Cancel
• The power is increased while the one-touch power maximizing switch is pressed. The function is
automatically deactivated when the switch is continuously pressed for more than 8.5 seconds.
PC360LC-10 10-207
Machine push-up function (PC300-PTL1-042-K-00-A)

2. Battery
3. Battery relay
4. Fusible link
5. Fuse box
7. Pump controller
9. Machine monitor
12. Supply pump
13. Sensors
17. Front pump
17a. Servo
17b. LS valve
17c. PC valve
18. Rear pump
18a. Servo
18b. LS valve
18c. PC valve
10-208 PC360LC-10
19. Control valve

23. Machine push-up solenoid valve
24. Machine push-up switch
Input/Output signal
d. CAN signal
e. 2-stage relief solenoid valve drive signal
f. Pump oil pressure sensor signal
g. One-touch power maximizing switch signal
j. Sensor signals
Function
• The machine push-up function allows the operator to increase the boom pushing force that is required for
ditching or square hole digging in hard ground by operating machine push-up switch (24).
Switch operation 2-stage safety valve function
Setting of safety valve at boom cylinder head

OFF
14.7 MPa {150 kg/cm2}
Setting of safety valve at boom cylinder head

ON
28.4 MPa {290 kg/cm2}
PC360LC-10 10-209
Auto-deceleration function (PC300-AF60-042-K-00-A)
1. Pump controller
3. Machine monitor
5. Supply pump
6. Sensors
9. Main pump
10. Control valve
Input/Output signal
a. CAN signal
b. Oil pressure sensor signal
c. Oil pressure switch signal
d. 1st throttle signal
e. Supply pump control signal
f. Sensor signals
Function
• When all the control levers are set to NEUTRAL for waiting for a dump truck or work, the engine speed is
automatically reduced to a controlled speed, and fuel consumption and noise are lowered.
10-210 PC360LC-10
• When any control lever is operated, the engine speed returns immediately to the speed that is set by the
fuel control dial.
Operation
Control lever: NEUTRAL

• If all the control levers are in NEUTRAL position for four seconds or more while the engine runs at a speed
higher than approx. 1,000 rpm, the engine speed is decelerated to approx. 1,000 rpm and held at the level
until any control lever is operated.
When any control lever is operated

• If any control lever is operated when the engine speed is maintained at the controlled speed (approx.
1,000 rpm), the engine speed increases immediately to the speed set with the fuel control dial.
A: All work equipment control levers in NEUTRAL

B: Work equipment control levers in OPERATION
C: Fuel control dial set speed
D: Controlled engine speed (approx. 1,000 rpm)
E: 4 seconds
F: Max. 2 seconds
G: Max. 1 second
PC360LC-10 10-211
Engine automatic warm-up function (PC300-AP13-042-K-00-A)

2. Battery
3. Battery relay
4. Fusible link
5. Fuse box
7. Pump controller
9. Machine monitor
10. Air conditioner unit
13. Supply pump
14. Sensors
15. Hydraulic oil temperature sensor
16. Front pump
16a. Servo
16b. LS valve
16c. PC valve
17. Rear pump
17a. Servo
17b. LS valve
17c. PC valve
18. Control valve
10-212 PC360LC-10

Input/Output signal
d. CAN signal
e. Hydraulic oil temperature signal
f. 1st throttle signal
g. Supply pump control signal
h. Sensor signals
PC360LC-10 10-213
Function
• This is a function that raises the engine speed automatically to warm up the engine if the coolant
temperature is low after start-up of the engine.
• There are two types of the engine automatic warm-up function depending on the purpose; one is "Heater
warm-up" and the other is "Normal warm-up".
• The purpose of the heater warm-up is to raise the coolant temperature and improve the heater efficacy.
• The purpose of the normal warm-up is to warm up the engine to prevent it from being damaged by
operation in low temperature.
Operating conditions 1
Machine specification: with air conditioner
Air conditioner: blower "ON"
Coolant temperature: Max. 50 °C
Ambient temperature: below 5 °C
Manual stationary regeneration OFF
Oot accumulation: Max. 4 g/l
O O
If any of operating conditions 1 is not satisfied
Heater warm-up is disabled (normal warm-up) When all of operating conditions 1 are
Operating conditions 2 (all required for operation) satisfied
Coolant temperature: Max. 30 °C Heater warm-up is enabled
Engine speed: Max. 1,250 rpm
O O
Operation Operation
Engine speed: 1,250 rpm Engine speed: 1,300 rpm
O O
Cancellation conditions (either one required) Conditions for cancellation
Coolant temperature: Min. 30 °C
Auto Coolant temperature: Min. 55 °C
Duration of automatic warming-up: Min.
10 minutes or
Fuel control dial: held at over 70% of Ambient temperature: min. 10 °C
Manual maximum speed for 3 seconds or more
O O
Cancelled
Engine speed: as desired
10-214 PC360LC-10
Overheat prevention function (PC300-B717-042-K-00-A)
a See "Engine automatic warm-up function" section for system circuit diagram.
• This is a function that prevents overheat to protect the engine and hydraulic components by reducing load
on the pump and lowering the engine speed if the coolant or hydraulic oil temperature becomes too high.
Operating condition Operation and actions taken Conditions for cancellation

Hydraulic oil temperature:
Working mode: Travel (Hi Below 93 °C
Hydraulic oil temperature: o speed) o • Under above condition,
Min. 95 °C Engine speed: Leave as is. controller is returned to the
Travel speed: Down condition before operation of
function (automatic reset).

Coolant temperature: Below
100 °C
Coolant temperature: Min. Working mode: P and ATT/P
100 °C Hydraulic oil temperature:
o modes o Below 100 °C
or Engine speed: Leave as is. • Under above condition,
Hydraulic oil temperature: • Reduce pump delivery. controller is returned to the
Min. 100 °C condition before operation of

102 °C
Coolant temperature: Min. Working mode: P, E, B, ATT/P,
102 °C Hydraulic oil temperature:
o or ATT/E modes o Below 102 °C
or Engine speed: Leave as is. • Under above condition,
Hydraulic oil temperature: • Reduce pump delivery. controller is returned to the
Min. 102 °C condition before operation of

105 °C
Coolant temperature: Min. Hydraulic oil temperature:
Working mode: Any mode Below 105 °C
105 °C
o Engine speed: Low idle o Fuel control dial: Return to low
or
Alarm monitor: Lights up idle (MIN) position.
Hydraulic oil temperature:
Alarm buzzer: Sounds • Under above condition,
Min. 105 °C
controller is returned to the
condition before operation of
function (manual reset).
PC360LC-10 10-215
Turbocharger protection function

a See "Engine automatic warm-up function" section for system circuit diagram.
• This is a function that prevents seizure of the turbocharger by restricting the engine speed if the engine
speed is increased hastily when starting the engine.
Operating condition Operation

o Turbocharger protection
Engine oil pressure: below 50 kPa {0.51 kg/cm2}
(See the following figure.)
A: Start engine
B: Duration of turbocharger protection (approximately 0 to 20 sec.)
C: Modulating time (approx. 1 sec.)
D: 500 rpm
E: Approximately 1,000 rpm
F: 2,050 rpm (*1)
*1: Working mode: P mode
Fuel control dial: Full speed (MAX) position
When the swing lock is ON.
10-216 PC360LC-10
Swing control function (PC300-JA01-042-K-00-A)

2. Battery
3. Battery relay
4. Fusible link
5. Fuse box
6. swing brake cancel switch
7. Swing lock switch
8. Pump controller
9. Machine monitor
12. Main pump
13. Control valve
14. Swing motor
14a. 2-stage relief valve
15. Swing holding brake solenoid valve
16. 2-stage swing relief solenoid valve
Input/Output signal
a. Swing holding brake cancel switch signal
b. Swing holding brake solenoid valve drive signal
c. CAN signal
d. Swing lock switch signal
e. 2-stage swing relief solenoid valve drive signal
f. Oil pressure sensor signal
g. Oil pressure switch signal
PC360LC-10 10-217
Function
Swing lock and swing holding brake function
• Swing can be locked at any position by turning ON swing lock (manual) switch (1).
• The swing holding brake (automatic) is linked and prevents hydraulic drift from occurring after the swing
stops.
• Linked with the L.H. and R.H. work equipment control levers and attachment control pedals operations,
the swing holding brake is canceled to reduce the load on the swing equipment during excavation work.
Swing lock switch OFF ON

Swing lock monitor Lights-out Lights-up
Function Swing holding brake Swing lock
• When the L.H. and R.H. work equipment
control levers and attachment control
• Swing holding brake applies and
pedals are set to NEUTRAL position, the
locks the swing.
swing holding brake works in approx. 7
• Even if the L.H. work equipment
sec.
Operation control lever is operated for swing,
• When the L.H. and R.H. work equipment
the swing holding brake cannot be
control levers or attachment control
canceled, and the upper structure
pedals are operated, the swing holding
does not swing.
brake is canceled and the upper
structure becomes free to swing.
A: When work equipment control lever or attachment control pedal is operated (swing brake canceled)
B: When work equipment control levers and attachment control pedals are in the NEUTRAL position
C: Swing holding brake applied
D: Approx. 7 sec.
Swing holding brake release function

• If the controller has malfunction and no swing is possible because the swing holding brake does not work
properly, operating swing brake cancel switch (2) releases the swing holding brake and allows swing
operation.
a: Release (Malfunction)
b: Normal
10-218 PC360LC-10
Swing holding brake Release Normal

cancel switch (When controller has malfunction) (When controller is normal)
Swing lock switch ON OFF ON OFF
Swing holding brake Swing holding brake
Swing brake Swing lock works Swing lock works
released (*) works
*1: Hydraulic brake applied by relief valve.

a Even if swing brake cancel switch (2) is set to the CANCEL (a) position, swing holding brake is not
released while swing lock switch is set to the ON position.
a When the swing holding brake is released, only the hydraulic brake with the relief valve is effective for
holding the upper structure. So, note that, when the swing stops on a slope, a hydraulic drift may occur.
a Swing brake cancel switch (2) is of the alternative type. When the switch is turned to the CANCEL (a)
position, the swing lock monitor on the machine monitor blinks.
Quick warm-up function

• If swing lock switch (1) is turned to the ON position, the pump cut-off function is cancelled and the main
relief pressure increases.
• If the work equipment hydraulic circuit is relieved with the main relief pressure increased, the hydraulic oil
temperature increases quickly and the warm-up time can be shortened.
Operating condition Main relief pressure
34.8 MPa {355 kg/cm2}
• Swing lock switch: ON O
37.2 MPa {380 kg/cm2}
2-stage swing relief function

• During swing acceleration, the set pressure of the 2-stage swing relief valve is changed to decrease the
flow rate to hydraulic relief and improve the fuel consumption ratio.
PC360LC-10 10-219
Operating condition Flow rate of hydraulic relief

• During swing acceleration 260 l/min
(excluding sharp change operation of swing O
direction) 100 l/min
Relation between set pressure and flow
A: Pilot pressure blocked (low-pressure setting)

B: Pilot pressure applied (high-pressure setting)
P: 27.9 MPa {285 kg/cm2}
Q1: 260 l/min
Q2: 100 l/min
Characteristics of 2-stage relief valve
A: Oil flow at low-pressure setting

B: Oil flow at high-pressure setting
C: Flow necessary for swing
Z: Area where the loss by relief flow is reduced (fuel consumption improved)
10-220 PC360LC-10
Travel control function (PC300-C7H1-042-K-00-A)
1. Pump controller
3. Machine monitor
5. Supply pump
6. Sensors
10. Travel alarm
11. Front pump
11a. Servo
11b. LS valve
11c. PC valve
12. Rear pump
12a. Servo
12b. LS valve
12c. PC valve
13. Control valve
14. Travel motor
PC360LC-10 10-221

17. LS-EPC valve
Input/Output signal
a. Oil pressure sensor signal
b. CAN signal
c. LS-EPC valve drive signal
d. Solenoid valve GND
e. Travel junction solenoid valve drive signal
f. Travel speed solenoid valve drive signal
g. Oil pressure sensor signal
h. Travel alarm buzzer operation signal
i. 1st throttle signal
j. Supply pump control signal
k. Sensor signals
10-222 PC360LC-10
Function
Travel speed selection function
1. Function to control pump during travel
• See " Engine and pump combined control function" for details.
2. Travel speed selection function
1) Manual selection with travel speed switch
If one of Lo, Mi and Hi is selected with the travel speed switch, the pump controller controls the pump
capacity and motor capacity at each gear speed as shown below to change the travel speed.
Travel speed selector switch Lo (Low speed) Mi (Medium speed) Hi (High speed)
Pump flow rate (%) 96 82 100
Motor capacity Max. Min. Min.
Travel speed (km/h) 3.2 4.5 5.5
2) Automatic selection by engine speed
If the engine speed is adjusted to 1,200 rpm on less with the fuel control dial, the travel speed changes
to Lo when the machine is travelling in Mi or Hi. and the travel speed will not change to Mi or Hi
afterwards.
3) Automatic change by pump delivery pressure
While traveling with the travel speed switch set to Hi or Mi, if the load increases by uphill travelling, or
so and the travel pressure goes above 32.3 MPa {330 kg/cm2} for more than 0.5 sec, the travel motor
capacity will automatically change to low speed (equivalent to Lo). The travel speed switch will stay at
Hi or Mi.)
If the load decreases by travelling on level ground or travelling downhill, and the travel pressure goes
below 18.6 MPa {190 kg/cm2} for more than 0.5 sec, the travel motor capacity will automatically
change and will return to Hi or Mi.
A: 18.6 MPa {190 kg/cm2}

B: 32.3 MPa {330 kg/cm2}
C: Min. 0.5 sec.
D: Min. 0.5 sec.
PC360LC-10 10-223
PPC lock function (PC300-PX16-042-K-00-A)

2. Battery
3. Battery relay
4. Fusible link
5. Fuse box
6. Starting switch
7. Lock lever
8. PPC lock switch
9. Main pump
10. Control valve
Function
• PPC lock switch is linked with the lock lever and is turned off when the lock lever is moved to the "LOCK"
position.
• When the PPC lock switch is turned off, current to the PPC lock solenoid valve is shut off. Even if each
control lever or pedal is operated, the work equipment and machine do not move.
10-224 PC360LC-10
Oil flow adjuster function for attachment (PC300-PT24-042-K-00-A)
(for machine with provision for attachment)

2. Battery
3. Battery relay
4. Fusible link
5. Fuse box
7. Pump controller
9. Machine monitor
12. Supply pump
13. Sensors
15. Front pump
15a. Servo
15b. LS valve
15c. PC valve
16. Rear pump
16a. Servo
16b. LS valve
16c. PC valve
17. Control valve
PC360LC-10 10-225

18. Attachment selector solenoid valve
20. Oil flow adjuster EPC valve for attachment
23. Attachment circuit selector valve
24. Attachment
25. Accumulator
26. Accumulator
Input/Output signal
d. CAN signal
e. Attachment selector solenoid valve drive signal
f. Oil flow adjuster EPC valve drive signal for attachment
g. Oil pressure switch signal
j. Sensor signals
Function
• Setting of the working mode and oil flow rate on the machine monitor controls the oil flow to the
attachment when the attachment control pedal is fully depressed.
• Attachment operation switches depending on the working mode as shown below.
Working mode Attachment operation
ATT/P, ATT/E Double-acting
B Single-acting
10-226 PC360LC-10
System component parts (ALL-RA1C-001-K-00-A)
Engine controller (PC220-AP70-041-K-00-A)
Input and output signals (PC300-AP70-03C-K-00-A)

• The following is the list of the symbols used for signal classification in the input/output signal table.
A: Power supply
B: Input
C: Ground/Shield/Return
D: Output
E: Communication
DRC26-60P(1)[ECM J1(CN-CE01)]
Signal name Signal

Pin No.
classification
1 LIFT PUMP D
2 NC(*1) –
3 Crankcase pressure sensor B
4 NC(*1) –
5 Charge temperature sensor (+) B
6 Intake temperature sensor B
7 CAN_C(+) E
8 CAN_B(+)/komnet_r E
9 Buckup sensor (+) B
10 NC(*1) –
11 LIFT PUMP RETURN C
12 NC(*1) –
13 GND C
14 Coolant temperature sensor B
15 Charge pressure sensor B
PC360LC-10 10-227
Signal name Signal

Pin No.
classification
16 Ambient pressure sensor B
17 CAN_C(–) E
18 CAN_B(–)/komnet_r E
19 NC(*1) –
20 NC(*1) –
21 Sensor power supply (12 V) A
22 GND C
23 Mass air flow sensor B
24 WIF sensor B
25 NC(*1) –
26 NE sensor (+) B
27 NC(*1) –
28 NC(*1) –
29 NC(*1) –
30 IMV(+) D
31 Oil pressure switch B
32 GND C
33 NC(*1) –
34 NC(*1) –
35 NC(*1) –
37 Ne sensor (–) C
38 NC(*1) –
39 NC(*1) –
40 IMV(–) C
41 NC(*1) –
42 NC(*1) –
43 Injector #4 (+) D
49 NC(*1) –
50 NC(*1) –
51 NC(*1) –
52 NC(*1) –
53 Injector #4 (–) C
59 GND C
*1: Never connect these pins. Malfunctions or failures may occur.
DRC26-60P(2)[ECM J2(CN-CE02)]
Pin No. Signal name Input/output
1 NC(*1) –
2 NC(*1) –
3 NC(*1) –
10-228 PC360LC-10

4 NC(*1) –
5 NC(*1) –
6 EGR valve solenoid (+) D
7 NC(*1) –
8 NC(*1) –
9 NC(*1) –
10 KVGT solenoid (+) D
11 NC(*1) –
12 NC(*1) –
13 NC(*1) –
14 NC(*1) –
15 NC(*1) –
16 EGR valve solenoid (-) C
17 NC(*1) –
18 GND C
19 NC(*1) –
20 KVGT solenoid (-) C
21 GND C
22 NC(*1) –
23 NC(*1) –
24 CAN_B(+)/RES E
25 CAN_B(–)/RES E
26 NC(*1) –
27 NC(*1) –
28 NC(*1) –
29 NC(*1) –
32 KVGT speed sensor (+) B
33 KVGT speed sensor (-) C
34 Exhaust manifold left sensor B
35 NC(*1) –
36 NC(*1) –
37 NC(*1) –
38 KVGT position sensor B
39 NC(*1) –
40 NC(*1) –
41 NC(*1) –
42 NC(*1) –
43 NC(*1) –
44 Common rail pressure sensor B
45 NC(*1) –
46 GND C
47 GND C
48 EGR orifice temperature sensor B
49 NC(*1) –
50 NC(*1) –
51 NC(*1) –
52 NC(*1) –
53 NC(*1) –
54 NC(*1) –
55 NC(*1) –
PC360LC-10 10-229

56 NC(*1) –
57 NC(*1) –
58 NC(*1) –
59 EGR valve lift sensor (SIG) B
60 NC(*1) –
DRC26-60P(3)[CN-CE03]
1 Unswitched power supply (24 V) A
3 Starting switch ACC signal B
4 Intake air heater relay D
5 NC(*1) –
6 NC(*1) –
7 NC(*1) –
8 NC(*1) –
9 System operating lamp D
10 NC(*1) –
13 GND C
14 NC(*1) –
15 NC(*1) –
16 NC(*1) –
17 CAN_A(+)/komnet_c E
18 CAN_A(–)/komnet_c E
19 GND C
20 NC(*1) –
21 GND C
22 GND C
23 NC(*1) –
24 NC(*1) –
25 NC(*1) –
26 NC(*1) –
27 NC(*1) –
28 NC(*1) –
29 NC(*1) –
30 NC(*1) –
31 GND C
32 GND C
33 NC(*1) –
34 NC(*1) –
35 NC(*1) –
36 NC(*1) –
37 NC(*1) –
38 NC(*1) –
39 NC(*1) –
40 NC(*1) –
41 GND C
43 GND C
10-230 PC360LC-10

44 NC(*1) –
45 KDOC inlet temperature sensor B
46 NC(*1) –
47 NC(*1) –
48 KDOC outlet temperature sensor B
49 Idle validation signal 1 B
50 Idle validation signal 2 B
51 Throttle signal B
53 NC(*1) –
54 KDPF outlet temperature sensor B
55 KDPF differential pressure sensor B
56 NC(*1) –
57 NC(*1) –
58 KDPF outlet pressure sensor B
59 NC(*1) –
60 NC(*1) –
PC360LC-10 10-231
Pump controller (PC-C3V1-041-K-00-A)
Pump controller input and output signals (PC300-C3V1-03C-K-00-A)

AMP-81P[CN-CP01]
1 Unswitched power supply (24 V) Input
2 Unswitched power return Input
3 Window washer Output
4 Unswitched power supply (24 V) Input
5 Unswitched power return Input
6 Potentiometer power supply (5 V) Output
7 CAN(R)_H Input/output
8 Service oil pressure sensor Input
9 (*1) –
10 1st ATT potentiometer 2 Input
11 Front pump oil pressure sensor Input
12 Right swing PPC oil pressure sensor Input
13 Boom LOWER PPC oil pressure switch Input
14 Arm IN PPC oil pressure sensor Input
15 Left travel REVERSE PPC oil pressure sensor Input
16 Over Load sensor Input
17 (*1) –
10-232 PC360LC-10

18 GND (analog signal) –
19 (*1) –
20 Swing lock switch Input
21 Model Select 3 Input
22 (*1) –
23 Breaker switch Input
24 Starting switch ACC signal Input
25 (*1) –
26 CAN(R)_L Input/output
27 Sensor power supply Output
28 Hydraulic oil temperature sensor Input
29 2nd ATT potentiometer 2 Input
30 Rear pump oil pressure sensor Input
31 Left swing PPC oil pressure sensor Input
32 Boom RAISE PPC oil pressure sensor Input
33 (*1) –
34 Left travel FORWARD PPC oil pressure sensor Input
35 Service PPC oil pressure switch Input
36 (*1) –
37 Digital signal GND Input
38 (*1) –
39 Swing holding brake cancel switch Input
40 Model Select 2 Input
41 (*1) –
42 Knob switch Input
44 Pulse input GND Input
45 CAN(C)_H Input/output
46 GND (analog signal) Input
47 Analog signal GND Input
48 1st ATT potentiometer 1 Input
49 Front pump swash plate sensor Input
50 Bucket DUMP PPC oil pressure switch Input
51 Arm OUT PPC oil pressure sensor Input
52 (*1) –
53 Right travel reverse oil pressure sensor Input
54 Quick coupler alarm switch Input
55 (*1) –
56 Wiper motor reverse (W) Input
57 Overload alarm effective switch Input
58 Model Selection 5 Input
60 (*1) –
61 Starting switch C signal Input
62 External start signal Input
63 SV potentiometer power supply –
64 CAN(C)_L Input/output
67 2nd ATT potentiometer 1 Input
68 Rear pump swash plate sensor Input
69 Bucket CURL PPC oil pressure sensor Input
PC360LC-10 10-233

71 (*1) –
72 Right travel FORWARD PPC oil pressure sensor Input
73 (*1) –
74 (*1) –
75 Wiper motor stop (P) Input
76 Cab front window open limit switch Input
78 (*1) –
79 PPC lock switch Input
81 Digital signal GND Input
AMP-40P[CN-CP02]
82 (CAN shield) –
83 (*1) –
84 (*1) –
85 Travel junction solenoid valve Output
86 Attachment selector solenoid valve Output
87 2nd service EPC-L Output
88 LS-EPC valve Output
89 Merge-divider EPC valve (LS) Output
90 (*1) –
91 (*1) –
92 (*1) –
93 Travel speed increase solenoid valve Output
94 2-stage swing relief solenoid valve Output
95 2nd service EPC-R Output
96 Front pump PC-EPC valve Output
97 Oil flow adjuster EPC valve for attachment Output
98 (*1) –
99 (*1) –
100 System-in-use signal Output
101 Swing holding brake solenoid valve Output
102 1st service EPC-L Output
103 (*1) –
104 Rear pump PC-EPC valve Output
105 (*1) –
106 (*1) –
107 Travel alarm Output
108 Battery relay drive Output
109 2-stage relief solenoid valve Output
110 1st service EPC-R Output
111 (*1) –
112 Merge-divider EPC valve (main) Output
113 Variable back pressure solenoid valve Output
114 Wiper motor (-) Output
115 GND (solenoid) Input
116 Solenoid power supply Input
10-234 PC360LC-10

119 Wiper motor (+) Output
PC360LC-10 10-235
Fuel control dial (PC-AGJ7-041-K-01-A)
1. Knob
2. Dial
3. Spring
4. Ball
5. Potentiometer
6. Connector
Function (PC300-AGJ7-042-K-00-A)
• This dial is installed in the right console box. Turning knob (1) causes potentiometer (5) shaft to rotate.
• As the potentiometer shaft is turned, the resistance of the variable resistor in potentiometer (5) changes
and a throttle signal is sent to the engine controller.
• The hatched areas in the graph are abnormality detection areas. If the throttle voltage is within the area,
the engine speed drops down to low idle.
10-236 PC360LC-10
Resistor for PC-EPC valve (PC-C3VR-041-K-00-A)

1. Resistance
2. Connector
Specifications (PC220-C3VR-030-K-00-A)
Resistance: 20 z
Function (PC-C3VR-042-K-00-A)
• When the emergency pump drive switch or the emergency work equipment drive switch is turned to "ON"
position, this resistor sends an electric current to each PC-EPC valve that is appropriate for their condition.
a No electric current flows in the normal condition.
CAN terminating resistor (PC220-Q2V1-041-K-00-A)
a CAN: Abbreviation for Controller Area Network
1. Connector (with built-in resistor)
Specifications (PC220-Q2V1-030-K-00-A)
Resistance: 120 z
Function (PC220-Q2V1-042-K-00-A)
• This resistance controls the reflection of the high-frequency signals at the end of CAN communication line
not to generate noise on the CAN communication signals sending and receiving between controllers.
PC360LC-10 10-237
a If this resistance is missing, an error occurs on CAN communication and the machine cannot be
operated.
Engine oil pressure switch (PC-ABK6-041-K-00-A)
1. Connector
2. Sensor
3. O-ring
Specifications (PC220-ABK6-030-K-00-A)
Contact type: Normally closed
Function (PC-ABK6-042-K-00-A)
• This oil pressure switch is installed to the cylinder block. It detects engine oil pressure, and turns the
switch to "ON" position when the pressure goes below the specified value.
10-238 PC360LC-10
PPC oil pressure switch (PC-E610-041-P-00-A)
1. Plug
2. Switch
3. Connector
Specifications (PC220-E610-030-P-00-A)
Contact type: Normally open
Operating (ON) pressure: 490 ± 98.1 kPa {5.0 ± 1.0 kg/cm2}
Resetting (OFF) pressure: 294 ± 49.0 kPa {3.0 ± 0.5 kg/cm2}
Function (PC220-E610-042-P-00-A)
• Two sensors are installed to attachment PPC valve. They detect PPC oil pressure during attachment
operation and turn the switch to "ON" position if the pressure is equal or higher than the specified
pressure.
PC360LC-10 10-239
Machine monitor system
Machine monitor system (PC-Q170-042-K-01-A)
1. Machine monitor
2. Battery
3. Pump controller
5. Air conditioner controller
6. KOMTRAX terminal
7. Sensors and switches
8. Wiper motor and window washer motor
9. Camera
Input and output signals
a. Power supply
b. CAN signal
c. Sensor and switch signals
d. Drive signal
e. Camera signal
Function
• The monitor system keeps the operator informed of all machine functions, by monitoring the machine
conditions by using the sensors and switches installed in various parts of the machine and processing
them instantly to display on the machine monitor.
10-240 PC360LC-10
The information displayed on the machine monitor falls into the following types:
1. Alarm when the machine has trouble
2. Machine status display (coolant temperature, hydraulic oil temperature, fuel level, etc.)
3. Display of camera image
• The switches on the machine monitor have an operating function to control the machine.
Machine monitor (PC-Q180-042-K-01-A)
Function
• The machine monitor has monitor display function, mode selection function and switch function for
electrical parts etc. Also it has an alarm buzzer.
• The machine monitor has a CPU (Central Processing Unit) in it to process, display, and output the
information.
• The machine monitor consists of a display and switches: the display is of LCD type, and the switches are
of flat sheet switch.
• If a failure occurs in the machine monitor itself, controller or wiring circuit between monitor and controller,
the monitor does not display properly.
Precautions on the machine monitor display

• One of the features of liquid crystal display panels is that there may be black spots (spots that do not light
up) or white spots (spots that stay lit up) on the screen. If there are fewer than 10 black or white spots, this
is not a failure or a defect. Products having 10 or less black or bright spots conform the product
specification; such the condition is quite normal.
• When the engine is started, the battery voltage may drop suddenly, depending on the ambient
temperature and the condition of the battery. In this case, the machine monitor display may go off for a
moment. However, this phenomenon is not a failure.
• Continuous operation of the machine monitor may display blue bright spots on the screen having a black
background; it is quite normal.
Blue bright spots can never be a problem as the screen has usually blue or white background. (White in
the LCD is made up of red, green and blue.)
Input and output signals (PC-Q180-03C-K-00-A)

070-18P[CN-CM01]
PC360LC-10 10-241
Pin No. Signal name Input/Output signal

1 Continuous power supply (24 V) Input
2 Continuous power supply (24 V) Input
3 GND (continuous power supply) -
4 GND (continuous power supply) -
5 External start signal Input
6 Starting motor cut-off relay (for personal code) Output
7 (*1) -
8 System operating lamp Input/Output
9 Lamp switch Input
10 Starting switch (ACC) Input
11 Starting switch (C) Input
12 Preheating Input
13 Engine shutdown secondary switch Input
14 (*1) -
15 Fuel level sensor Input
16 Charge level (Alternator R terminal) Input
17 (*1) -
18 (*1) -
070-12P [CN-CM02]
1 Seat belt alarm switch Input
2 Engine oil level sensor Input
3 Radiator coolant level sensor Input
4 Air cleaner clogging sensor Input
5 Swing lock switch Input
6 (*1) -
7 CAN (C) terminating resistor terminal -
8 CAN (C)_H Input/Output
9 CAN (C)_L Input/Output
10 CAN (R) terminating resistor terminal -
11 CAN (R)_H Input/Output
12 CAN (R)_L Input/Output
070-20P [CN-CM03]
1 (*1) -
2 (*1) -
3 (*1) -
4 (*1) -
5 (*1) -
6 (*1) -
7 (*1) -
8 (*1) -
9 (*1) -
10 (*1) -
11 (*1) -
12 (*1) -
13 (*1) -
14 (*1) -
10-242 PC360LC-10

15 (*1) -
16 (*1) -
17 (*1) -
18 (*1) -
19 (*1) -
20 (*1) -
070-8P [CN-CM04]
1 Camera power supply (8 V) Output
2 Camera NTSC signal 1 Input
5 GND (Camera power supply) -
6 Switching camera 2 to original/mirror image Output
7 Switching camera 3 to original/mirror image Output
8 Shield GND -
PC360LC-10 10-243
Display (PC300-Q1LA-042-K-00-A)
A: Standard screen
B: Check before starting screen
C: Screen for maintenance time reminder
D: Warning screen
E: Guidance screen
F: Camera image screen
a Camera image screen (F) shown in the figure is the illustration when two or more cameras are installed
1. Message monitor
2. KDPF regeneration monitor
3. Engine stop monitor
4. Seat belt monitor
5. Air conditioner monitor
6. Wiper monitor
10-244 PC360LC-10
7. Swing lock monitor

8. Preheating monitor
9. Service meter
10. Auto-deceleration monitor
11. Working mode monitor
12. Travel speed monitor
13. Fuel level gauge
14. Fuel level monitor
15. ECO gauge
16. Fuel consumption gauge
17. Hydraulic oil temperature monitor
18. Hydraulic oil temperature gauge
19. Engine coolant temperature monitor
20. Engine coolant temperature gauge
21. Radiator coolant level monitor
22. Charge level monitor
23. Engine oil pressure monitor
24. Engine oil level monitor
25. Air cleaner clogging monitor
26. Water separator monitor
27. Clock
28. Maintenance time warning monitor
29. System condition monitor
30. Action level monitor
31. ECO guidance
PC360LC-10 10-245
Gauge
Gauge Item displayed Description Remarks
Tempera- Back- • Indicates corresponding
Range ture ground temperature range.
(°C) color • Alarm buzzer sounds when the
(*1) temperature exceeds 105.°C
W1 105 Red • If the monitor background
Engine coolant W2 102 Red
temperature appears white, warm-up the
gauge W3 100 Blue engine.
W4 85 Blue
W5 60 Blue
W6 30 White
Tempera- Back- • Indicates corresponding
Range ture ground temperature range.
(°C) color • Alarm buzzer sounds when the
(*1) temperature exceeds 105.°C
H1 105 Red • If the monitor background
Hydraulic oil H2 102 Red
temperature appears white, warm-up the
gauge H3 100 Blue hydraulic components.
H4 85 Blue
H5 40 Blue
H6 20 White
Back- • Indicates corresponding fuel
Range Quantity (l) ground level.
color
(*1) F1 462 Blue
Fuel level F2 347 Blue
gauge F3 278 Blue
F4 139 Blue
F5 100 Blue
F6 56 Red
Segment Load level • Indicates instantaneous fuel
Light to consumption (average of fuel
Green 1 to 8 consumption per 3 seconds) in
medium
(*2) 10 steps.
ECO gauge (It is displayed when the user
Orange 9, 10 Heavy menu's"Guide mode
ECO"o"Configurations"o"ECO
gauge" display is set.)
• Indicates accumulated engine
operating hours (while the
Service meter
00000.0 h to 99999.9 h alternator is running).
reading
• (F4 switch changes it to clock
display.)
• Displays time.
• 12-hour display (AM/PM) • (F4 switch changes it to service
Clock • 24-hour display meter display.)
• Indicates average fuel

(*2) consumption.
• one day • (Display is switched when the
Fuel • Split user menu's"Guide mode
consumption • None ECO"o"Configurations"o"Aver-
gauge age Fuel Consumption
Display"display is set.)
*1: If the gauge signal is not available due to open circuit in CAN communication line, the gauge pointer goes
off.
*2: Display item is switched with the item in the user menu's ECO guidance oDisplay setting.
10-246 PC360LC-10
Alarm monitor
Description
Monitor
Item Action
Symbol display Remarks
displayed Range level
(Background
monitor
color)
102 °C or Lights up • Background color changes
(red) L02 depending on the temperature
above
(*1) Min. 30 °C or Lights up detected.
Engine - • Alarm buzzer sounds when the
below 102 °C (blue)
coolant temperature exceeds 105 °C.
temperature Lights up • If the monitor background
Below 30 °C - appears white, warm-up the
(white)
engine.
102 °C or Lights up • Background color changes
(red) L02 depending on the temperature
above
(*1) Min. 20 °C or Lights up detected.
- • Alarm buzzer sounds when the
Hydraulic oil below 102 °C (blue)
temperature exceeds 105 °C.
temperature • If the monitor background
Lights up
Below 20 °C - appears white, warm-up the
(white)
hydraulic components.
Lights up • Background color changes
Below 56 l -
(*1) (red) depending on the remaining
Lights up fuel level.
Fuel level -
Min. 56 l (blue)
When • When an error is detected with
abnormal the engine stopped, the
(*1) Lights up (*3) monitor lights up on the
(When below (yellow)
Coolant specified L01 screen.
Level level)
When normal Lights out -
When charge • The monitor lights up on the
is defective screen and alarm buzzer
(*1) (Charge Lights up sounds when failure is
(red) L03 detected while the engine
Battery voltage <
charge battery running.
voltage)
When • The monitor lights up on the
abnormal screen and alarm buzzer
(*1) Lights up sounds when failure is
(When below (red) L03
Engine oil specified detected while the engine
pressure level) running.
abnormal the engine stopped, the
(*1) Lights up (*3) monitor lights up on the
(When below (yellow)
Engine Oil specified L01 screen.
Level level)
abnormal the engine running, the monitor
(*1) Lights up (*3) lights up on the screen.
(When above (yellow)
Air cleaner specified L01
clogging level)
PC360LC-10 10-247
Description
Monitor
Item Action
(Background
monitor
color)
abnormal the engine running, the monitor
(There is lights up on the screen.
(*1) water Lights up
-
Water collected (red)
separator above the
specified
amount.)
When • The display changes
exceeding Lights up depending on the time to/after
-
maintenance (red) the maintenance.
time • After the starting switch is
Maintenance (*2) turned to the ON position, the
time warning monitor turns on if the monitor
When Lights up
exceeding - light-up conditions are met,
(yellow) and then goes out in 30
maintenance
notifying time seconds.
When action • When failure is detected in the
level L04 or Lights up L04 and machine system, the monitor
L03 is (red) L03 lights up.
System
detected • When the background color is
condition
When action Lights up (*3) red, the alarm buzzer sounds.
level L01 is (yellow)
detected L01
level L04 or Lights up L04 and engine system, the monitor
Condition of L03 is (red) L03 lights up.
engine detected • When the background color is
system When action red, the alarm buzzer sounds.
Lights up (*3)
detected L01
level L04 or Lights up L04 and hydraulic system, the monitor
hydraulic detected • When the background color is
Lights up (*3)
detected L01
level L04 or Lights up L04 and KDPF system, the monitor
KDPF detected • When the background color is
Lights up (*3)
detected L01
When action • The monitor lights up when
level L04 or Lights up soot is accumulated inside
(red) L03
Accumula- L03 is KDPF or cleaning function is
tion of soot detected abnormally degraded.
on KDPF When action Lights up (*3) When the background color is
level L01 is (yellow) red, the alarm buzzer sounds.
detected L01
10-248 PC360LC-10
Description
Monitor
Item Action
(Background
monitor
color)
• The monitor lights up and
Engine When engine Lights up alarm buzzer sounds when
overspeed overspeed is (red) L02 engine overspeed is detected.
detected
Condition of • When failure is detected in the

air When air Lights up (*3) air conditioner system, the
conditioner conditioner is (yellow) L01
monitor lights up.
system abnormal
When action Lights up • When failure is detected on the

level L04 is (red) L04 machine, the monitor lights up.
detected When the background color is
When action Lights up red, the alarm buzzer sounds.
level L03 is (red) L03
detected
Action level
When action Lights up
level L02 is (red) L02
detected
When action Lights up (*3)
detected L01
*1: It is included in the check before starting items. After the staring switch is turned to the ON position, the
monitor turns on for two seconds, and changes to the standard screen if no failure is found.
*2: The time of warning is changeable through the items in Maintenance mode display setting of the service
mode.
*3: Monitor goes out after lighting up for two seconds.
PC360LC-10 10-249
Pilot monitor
Symbol Item displayed Description Remarks
• It operates automatically at a • Indicates
low temperature. preheat
Automatic (Symbol lights up as long as operating
preheating for approx. 30 seconds) condition.
• It goes out after the engine is
started.
Elapsed time
Preheat after turning the
starting switch to Monitor display
HEAT
Manual (Preheating)
preheating Lights up
0 to 30 sec.
30 to 40 sec. Blink
After 40 sec. or
Lights out
longer
One-touch • Indicates the
power max. Monitor display operating
One-touch switch condition of one-
power Lights up touch power
maximizing. ON (Goes off if pressed for 8.5 maximizing
seconds) function.
OFF Lights out
Swing holding • Indicates swing
Swing lock Monitor display
brake cancel lock operating
switch
switch condition.
Swing lock OFF OFF Lights out
ON OFF Lights up
OFF ON Blink
ON ON Blink
• Indicates front
INT: Intermittent
window wiper
Wiper ON: Continuous operating
Lights out: Stop condition.
• Indicates air
Lights up: ON conditioner and
Air conditioner air blower
Lights out: OFF operating
condition.
• Indicates
Lights up: Not fastened whether seat belt
Seat belt is fastened.
Lights out: Fastened
• Indicates the
Lights up: When engine is stopped engine operating
Engine stopped condition.
Lights out: While engine is running
• Indicates
KDPF Lights up: KDPF is being regenerated. regenerating
regeneration Lights out: KDPF regeneration is finished. condition of
KDPF.
• Indicates stop of
Stop of KDPF Lights up: KDPF regeneration is stopped. KDPF
regeneration Lights out: Stop of KDPF regeneration is cancelled regeneration.
10-250 PC360LC-10
Symbol Item displayed Description Remarks

• Condition of the
Message Lights up: There is unread message. message is
(Unread) Lights out: No message displayed.
Message • Condition of the

(No return Lights up: There is an already-read message but no message is
message, return message for it. displayed.
already-read Lights out: No message
message)
• Indicates auto-
Auto- Lights up: ON decelerator
decelerator Lights out: OFF operating
condition.
P: Heavy-duty operation • Displays working
E: Low-fuel consumption operation mode setting.
L: Fine operation
Working mode B: Breaker operation
ATT/P: Double-acting attachment operation
ATT/E: Double-acting attachment and low-fuel
consumption operation
• Displays travel
Lo: Low speed
speed setting.
Travel speed Med: Medium speed
Hi: High speed
• Guidance for
• Idle stop guidance
supporting
• Guidance on deterrence of hydraulic relief
machine
ECO guidance • E-mode recommendation guidance
operation and
• Partial throttle travel recommendation guidance
control are
• Low fuel level guidance
displayed.
PC360LC-10 10-251
Switches (PC-Q1C0-042-K-00-A)
No. Name Function Operation

Switches the auto-deceleration • When working mode is "L", this switch
Auto-deceleration function ON/OFF. is always "OFF" after engine started.
1 switch OFF io ON
Lights up: ON
[Numeric keypad: 1]
Lights out: OFF
Displays the working mode selector P: Heavy-duty operation
screen. E: Low-fuel operation
(*1) L: Fine operation
Working mode selector B: Breaker operation
2 switch ATT/P: Double-acting attachment
[Numeric keypad: 2] operation
ATT/E: Double-acting attachment and
low-fuel operation
Changes the travel speed. • Speed is sequentially changed as
Travel speed selector Lo lights up: Low speed shown below.
3 switch Lo (Low speed) o Mi (Medium
Mi lights up: Medium speed speed) o Hi (High speed) o Lo (Low
[Numeric keypad: 3]
Hi lights up: High speed speed)
Stops the alarm buzzer. • The alarm buzzer stops sounding.
Buzzer cancel switch (Some alarm buzzer does not stop • The alarm buzzer sounds again if
4 another error worth alarming is
[Numeric keypad: 4] sounding even if the switch is
pressed.) detected.
Operates the front glass wiper. • Pressing the switch sequentially
(*2) changes the wiper operation.
INT: Intermittent operation
5 Wiper switch OFF (Stop) o INT (Intermittent) o
ON: Continuous operation ON (Continuous) o OFF (Stop)
[Numeric keypad: 5]
Lights out: Holds in position
10-252 PC360LC-10
No. Name Function Operation

Sprays washer fluid onto the front ON: Washer fluid is sprayed and
window glass. windshield wiper works continuously.
[When wiper stops]
(*2) OFF: Windshield wiper works twice
continuously and stops after the switch is
6 Window washer switch
released.
[Numeric keypad: 6]
[When wiper operates intermittently]
OFF: Windshield wiper works twice
continuously and returns to intermittent
operation after the switch is released.
Fan switch (increase) Controls the air flow of the air • The air flow increases immediately
7a conditioner in 6 levels. after the air conditioner adjustment
[Numeric keypad: 7] screen appears.
(Low, Medium 1, Medium 2,
Medium 3, Medium 4 and High) • The air flow decreases immediately
7b Fan switch (decrease) after the air conditioner adjustment
screen appears.
Temperature control Controls the temperature inside the • The preset temperature increases
8a switch (raise) cab. immediately after the air conditioner
[Numeric keypad: 8] (18.0℃ to 32.0℃: Setting is adjustment screen appears.
Temperature control available in 0.5°C steps) • The preset temperature decreases
8b switch (lower) immediately after the air conditioner
[Numeric keypad: 0] adjustment screen appears.
Operates the air conditioner and air • The air flow, combination of vents,
(*3) flow with automatic operation. and selection of FRESH/RECIRC air
AUTO lights up: Automatic are automatically selected according
9 Auto switch
operation to the set temperature immediately
[Numeric keypad: 9] after the air conditioner adjustment
screen appears.
Selects the air conditioner ON/OFF. • Switches to the air conditioner
(*4) A/C ON lighted: Manual operation adjustment screen, and pressing it
10
Air conditioner switch Not lighting: Stop again switches ON/OFF.
OFF io ON
Changes the FRESH/RECIRC. • Switches to the air conditioner
FRESH/RECIRC air adjustment screen, and pressing it
11 changeover switch again switches FRESH/RECIRC.
RECIRC io FRESH
Selects the air vent mode from 6 • Switches to the air conditioner
modes. adjustment screen, and pressing it
1. Front vent again switches air vent mode.
1o2o3o4o5o6o1
2. Front and rear vents
12 Vent selector switch
3. Front, rear and foot vents
4. Foot vent
5. Foot and defroster vents
6. Defroster vent
Stops the fan and air conditioner. • The fan and air conditioner stop.
13 OFF switch
Lights OFF: OFF
14a Guidance icon
See "Guidance icon and function switch"
14b Function switch
*1: When the working mode is changed, the auto-decelerator function turns "ON".
*2: When the front window is open, the wiper and washer do not operate even if the switch is pressed.
*3: If temperature is set to 18.0°C or 32.0°C, the air flow from the fan is always set to "High" and does not
change even if the set temperature is reached.
*4: Air conditioner cannot be operated while the fan stops.
PC360LC-10 10-253
Guidance icon and function switch (PC-Q1C1-042-K-00-A)

• Functions available with the function switch vary depending on the guidance icon displayed above the
switch.
• No function is available if no guidance icon appears above the function switch.
• The following is the list of guidance icons and the functions displayed above the function switches.
Guidance
Item Function
icon
Selects user menu screen.
Background colors allow confirming the type of information
transmitted.
Selection of user mode • Gray: When the condition is normal
screen • Red: When soot accumulation abnormality (L3) is detected, or
exceeding maintenance interval
• Yellow: When soot accumulation abnormality (L1) is detected, or
exceeding maintenance interval warning
• Green: When there is unread KOMTRAX message
Switching clock/service Switches clock/service meter display.

meter
Switching to camera Switches to camera image display screen.

screen
Enters selected/setting item.

Background colors allow confirming the type of information
Enter transmitted.
• Gray: When the condition is normal
• Green: When energy saving guidance is displayed
Return Returns to the previous screen or status.
Selects the item right above the current item

Switching the select item
(To the bottom item from the top item.)
Selects the item right below the current item

(To the top item from the bottom item.)
Green arrow: Selects the item on the right side of the tab.
Switching the select item White arrow: Selects the item on the right side of the current item.
(To the leftmost item from the rightmost item.)
Green arrow: Selects the item on the left side of the tab.
Switching the select item White arrow: Selects the item on the left side of the current item.
(To the rightmost item from the leftmost item.)
Selects the page right above the current page.

(To the bottom page from the top page.)
10-254 PC360LC-10
Guidance
Item Function
icon
Selects the page right below the current page.

(To the top page from the bottom page.)
Clear Clears selected/displayed item.
Sets selected item back to default.

Restores default value
(Used for screen adjustment.)
Set Performs setting.
Starts function.
Start (Used for starting measurement of split fuel consumption on the fuel
consumption display screen.)
Stops operation.
Stop (Used for stopping measurement of split fuel consumption on fuel
consumption display screen.)
Saving Saves setting
Switching to the name

Switches the current screen to the name setting screen
setting screen
Switching to ATT1 oil flow Switching the current screen to attachment 1 oil flow setting screen.
setting screen (Enabled only when attachments 1 and 2 are equipped)
Switching to ATT2 oil flow Switching the current screen to attachment 2 oil flow setting screen.
setting screen (Enabled only when attachments 1 and 2 are equipped)
Holds the value of the target item of monitoring.

HOLD
(Used when monitoring is turned on)
Resets the currently held value of the target item of monitoring.

Resetting the hold
(Used when monitoring is turned on)
Switching the fuel

Switches the graphs on the fuel consumption record screen.
consumption record screen
Switching to oil flow setting Switches to the attachment and breaker oil flow setting screen.
screen
PC360LC-10 10-255
Guidance
Item Function
icon
Switches to the currently occurring failures list screen.
Switching to the currently Background colors allow confirming the type of information
occurring failures list transmitted.
screen • Red: When an action level of L2, L3 or L4 is displayed
• Yellow: When the action level of L1 is displayed
Display No. 1 camera Selects No. 1 camera image display screen.

screen

screen

screen
Display No. 1 and No. 2 Display both images of No. 1 and No. 2 cameras simultaneously.
camera screens
10-256 PC360LC-10
Operator mode function (PC-Q193-042-K-00-A)

• The operator can select the information to be displayed usually on the screen and the function to be used
by operating the switches.
Display and setting of some functions require special operation of the switch.
• Items available in the operator mode are as follows:
Category Display order (*2)
Item
(*1) V W X Y Z
KOMATSU logo screen 1 1 1 1 1
Password input screen 2 — — — —
Breaker mode check screen — — 2 — —
Checks before starting screen 3 2 3 2 2
Warning screen after check before starting — — — 3 —
A — — — —
Overdue maintenance time item screen 3
Working mode and travel speed check screen 4 3 4 4 4
Standard screen 5 4 5 5 5
Engine shutdown secondary switch screen
End screen
Selecting auto-deceleration function
Selecting working mode
Selecting travel speed
Stopping alarm buzzer
Operating windshield wiper
Operating window washer
Operating air conditioner
Operating camera mode display
B Switching between clock display and service meter display
Checking maintenance information
Setting and displaying user menu
• "ECO Guidance"
• "Machine Setting"
• "KDPF Regeneration"
• "Maintenance"
• "Monitor Setting"
• Message display (including KOMTRAX messages for user)
Displaying ECO guidance
Displaying caution monitor
C
Displaying KDPF regeneration
Displaying action level and failure code
LCD (Liquid Crystal Display) display condition checking function
D Service meter reading checking function
Access restriction setting/password changing function
*1: The items available in the operator mode are categorized as shown below.
A: Displays that appear since starting switch is turned to "ON" position until the standard screen appears, and
the displays that appear after starting switch is turned to "OFF" position .
B: Displays that appear when the switch on the machine monitor is operated.
C: Displays when a certain condition is satisfied
D: Displays that require special switch operations.
*2: Display sequence from "ON" of starting switch to the standard screen varies depending on the settings
and conditions of the machine as follows:
V: When engine start lock is set effective
W: When engine start lock is disabled
X: When working mode at start is set to "Breaker Mode (B)".
Y: When a failure is detected during check before starting.
PC360LC-10 10-257
Z: When a maintenance time overdue is detected for an item.

a For how to operate the operator mode functions, see the Operation and Maintenance Manual or "Operator
mode (Outline)" section in Testing and adjusting.
a For how to set the engine start lock on/off, see " Password setting/cancel manual" .
Service mode function (PC-Q194-042-K-00-A)

• The functions in this mode are not displayed usually on the screen. Information display and various
settings can be made only by the technician through the special operation of the switches.
This mode is used for special setting, testing, adjusting, or troubleshooting.
• Items available in the service mode are as follows:
Monitoring / Pre-defined
Monitoring / Custom
Abnormality Record "Mechanical Systems"
"Electrical Systems"
Maintenance Record
Maintenance Mode Setting
Phone Number Entry
Default "Key-on Mode"
"Unit"
"With/Without Attachment"
"Camera"
Diagnostic Tests "Cylinder Cut-out"
"Regeneration for Service"
"KDPF Memory Reset"
Adjustment "Pump Absorption Torque (F)"
"Pump Absorption Torque (R)"
"Low Speed"
"Attachment Flow Adjustment"
"Cal F pump swash plate sensor"
"Cal R pump swash plate sensor"
No Injection
KOMTRAX Settings "Terminal Status"
"GPS & Communication Status"
"Modem Status"
Service Message
a For how to operate the service mode functions, see "Service mode" section in Testing and adjusting.
10-258 PC360LC-10
KOMTRAX system
KOMTRAX system (PC300-Q210-042-K-00-A)
• The KOMTRAX system consists of the KOMTRAX terminal, communication antenna, and GPS antenna.
• This system sends various information on the machine via wireless communication. It allows operators of
the KOMTRAX to obtain the machine information in the office and to provide various services with the
customers.
• Information transmittable through the KOMTRAX system are as follows.
1. Operation map
2. Service meter reading
3. Location information
4.Abnormality record
and others.
a To provide the services, you need to make an arrangement for starting the KOMTRAX service separately.
KOMTRAX terminal (PC220-Q220-042-K-00-A)
Type: TC330
1. GPS antenna connection

2. Machine harness connection (070-18P)
PC360LC-10 10-259
KOMTRAX system
3. Machine harness connection (070-12P)

4. Communication antenna connection
Input and output signals (PC220-Q220-03C-K-00-A)

070-18P[CN-CK01]
1 (*1) -
2 (*1) -
3 (*1) -
4 (*1) -
5 (*1) -
6 (*1) -
7 (*1) -
8 (*1) -
9 (*1) -
10 CAN (C)_H Input/Output
11 CAN (C)_L Input/Output
12 (*1) -
13 (*1) -
14 External start signal Input/Output
15 System operation lamp Output
16 (*1) -
17 (*1) -
18 (*1) -
070-12P [CN-CK02]
1 GND -
2 GND -
3 Starting switch (ACC) Input
4 Alternator (R) Input
5 (*1) -
6 Power supply Input
7 Power supply Input
8 (*1) -
9 (*1) -
10 (*1) -
11 Starting switch (C) Input
12 (*1) -
Function (PC-Q220-042-K-00-A)
• This terminal utilizes satellite communications technology.
• The terminal is an equipment which transmits various machine information obtained through network
signals and input signals, as well as GPS positioning data. The terminal can transmit data via the
communication antenna.
• The status of the terminal can be checked by using the menu of "KOMTRAX setting" in the service mode
of the machine monitor .
• Use of KOMTRAX terminal must be limited for the countries in which such communication is allowed.
• This terminal has LED lamps and 7-segment lamp indicator used for testing and troubleshooting on its
display section.
a When commencing operation of the KOMTRAX system or changing the country in which the system is
used, you must give notice about the name of the country to Komatsu Ltd.
10-260 PC360LC-10
KOMTRAX system
a When operating the system in Japan, install a terminal dedicated for use in Japan.
PC360LC-10 10-261
Sensor
Sensor (ALL-E700-001-P-00-A)
Ambient pressure sensor (ENG-AAP2-041-K-00-A)
1. Connector
2. Sensor
Function (ENG-AAP2-042-K-00-A)
• This sensor, installed to the air intake cover at the engine top side, detects the ambient pressure to output
the corresponding variable voltage.
Output characteristics
Charge (boost) pressure and temperature sensor (ENG-AAM7-041-K-00-A)
1. Connector
2. Sensor
3. O-ring
10-262 PC360LC-10
Sensor
Function (ENG-AAM7-042-K-00-A)
• This sensor is installed to the engine intake manifold. It detects the engine intake air pressure and its
temperature, and outputs signals as a variable voltage for pressure, and as variable resistance for
temperature.
a "Charge pressure and temperature" are the engine intake air pressure and temperature of a turbocharged
engine. These are also referred to as "boost pressure and temperature" or "intake air pressure and
temperature".
Coolant temperature sensor (ENG-BA87-041-K-00-A)
1. Connector
2. Sensor
3. O-ring
Function (ENG114-BA87-042-K-00-A)
• This sensor, installed on the cylinder head of the engine, converts the temperature variation into the
resistance variation, and outputs the corresponding signals.
PC360LC-10 10-263
Sensor
Ne (crankshaft) speed sensor (ENG114-AG42-041-K-00-A)
1. O-ring
2. Sensor
3. Connector
Function (ENG114-AG42-042-K-00-A)
• This sensor, installed to the rear left side of the engine cylinder block, outputs the pulse voltage due to the
gear rotation.
Bkup (camshaft) speed sensor (ENG-AG62-041-K-00-A)
1. O-ring
2. Sensor
3. Connector
Function (ENG114-AG62-042-K-00-A)
• This sensor, installed to the ring of cam shaft on the engine front cover, outputs the pulse voltage due to
the gear rotation.
10-264 PC360LC-10
Sensor
Common rail pressure sensor (ENG114-AE28-041-K-00-A)
1. Sensor
2. Connector
Function (ENG-AE28-042-K-00-A)
• This sensor, installed to the common rail in the engine, detects the fuel pressure to output the
corresponding variable voltage.
Exhaust manifold pressure sensor (ENG-AAN5-041-K-00-A)
1. O-ring
2. Sensor
3. Connector
Function (ENG-AAN5-042-K-00-A)
• This sensor, installed to the pressure outlet tube installed to the exhaust manifold of the engine, detects
the exhaust pressure to output the corresponding variable voltage.
PC360LC-10 10-265
Sensor
EGR orifice temperature sensor (ENG-A9U5-041-K-00-A)
EGR: Abbreviation for Exhaust Gas Recirculation
1. Connector
2. Sensor
3. Washer
Function (ENG-A9U5-042-K-00-A)
• This sensor, installed on the EGR gas piping between EGR cooler and EGR valve of the engine, converts
the temperature variation into the resistance variation, and outputs the corresponding signals.
EGR valve lift sensor (ENG-A9S2-041-K-00-A)
EGR: Abbreviation for Exhaust Gas Recirculation
1. O-ring (small)
2. O-ring (large)
3. Sensor
4. Connector
10-266 PC360LC-10
Sensor
Function (ENG-A9S2-042-K-00-A)
• This sensor, installed to EGR valve in the engine, detects the EGR valve opening to output the
• The relation between stroke and output voltage is as shown in the following graph.
KVGT speed sensor (ENG-AAQ4-041-K-00-A)
KVGT: Abbreviation for KOMATSU Variable Geometry Turbocharger
1. Sensor
2. O-ring
3. Connector
Function (ENG-AAQ4-042-K-00-A)
• This sensor, installed to KVGT in the engine, outputs the pulse voltage due to the rotation of KVGT
turbine.
a The 3-pole connector is applied for this sensor, however, available pins are the pin No. 1 and No. 2 only,
and it has no pin No. 3.
PC360LC-10 10-267
Sensor
KVGT position sensor (ENG-AAQ3-041-K-00-A)
KVGT: Abbreviation for KOMATSU Variable Geometry Turbocharger
1. O-ring (small)
2. O-ring (large)
3. Sensor
4. Connector
Function (ENG-AAQ3-042-K-00-A)
• This sensor, installed to KVGT in the engine, detects the location of the nozzle ring which is built in KVGT
to output the corresponding variable voltage.
10-268 PC360LC-10
Sensor
Mass air flow and temperature sensor (ENG-A96H-041-K-00-A)
1. Connector
2. O-ring
3. Sensor
Function (ENG-A96H-042-K-00-A)
• This sensor is installed to the outlet side of air cleaner, converts the variations of intake air flow and
temperature into the resistance variation, and outputs the corresponding signals.
a The "MAF (Mass Air Flow)" means the "intake air flow".
KDPF differential pressure and outlet pressure sensor (ENG-A9HL-041-K-00-A)
1. High-pressure port
2. Low-pressure port
3. Connector
4. Sensor
Function (ENG-A9HL-042-K-00-A)
• This sensor, installed to KDPF, detects the inlet pressure and outlet pressure of KDPF to output the
• The output pressure difference is the difference between the KDPF inlet pressure which is detected at
high-pressure port (1) and the KDPF outlet pressure which is detected at low-pressure port (2).
• The KDPF outlet pressure is output as a pressure which is detected at low-pressure port (2).
PC360LC-10 10-269
Sensor
KDOC inlet temperature sensor (ENG-A9HG-041-K-00-A)
KDOC: Abbreviation for KOMATSU Diesel Oxidation Catalyst
1. Sensor
2. Connector
Function (ENG-A9HG-042-K-00-A)
• This sensor, installed to the inlet side of KDOC which is built in KDPF, converts the temperature variation
into the resistance variation, and outputs the corresponding signals.
KDOC outlet temperature sensor (ENG-A9HH-041-K-00-A)
KDOC: Abbreviation for KOMATSU Diesel Oxidation Catalyst
1. Sensor
2. Connector
Function (ENG-A9HH-042-K-00-A)
• This sensor, installed to the outlet side of KDOC which is built in KDPF, converts the temperature variation
into the resistance variation, and outputs the corresponding signals.
10-270 PC360LC-10
Sensor
KDPF outlet temperature sensor (ENG-A9HJ-041-K-00-A)
1. Sensor
2. Connector
Function (ENG-A9HJ-042-K-00-A)
• This sensor, installed to the outlet side of KDPF, converts the temperature variation into the resistance
variation, and outputs the corresponding signals.
Crankcase pressure sensor (ENG-A18C-041-K-00-A)
1. Connector
2. Sensor
3. O-ring
Function (ENG-A18C-042-K-00-A)
• This sensor, installed to the inlet side of KCCV head portion, detects the crankcase pressure (blowby
pressure) to output the corresponding variable voltage.
PC360LC-10 10-271
Sensor
Engine oil level sensor (ENG-AB45-041-K-00-A)
1. Connector
2. Bracket
3. Float
4. Switch
Function (ENG-AB45-042-K-00-A)
• This sensor, installed on the side face of the oil pan, turns "OFF" by the lowered float, if the oil level
becomes lower than specified.
10-272 PC360LC-10
Sensor
Fuel level sensor (PC-AD41-041-K-00-A)
1. Connector
2. Float
3. Arm
4. Valve body
5. Spring
6. Variable resistor
Function (PC-AD41-042-K-00-A)
• This sensor is installed on the side face of the fuel tank. The float moves up and down according to the
fuel level.
• The movement of the float activates the variable resistor through the arm. As a result, the source voltage
is changed according to the resistance change due to the arm angle change and is output as a signal.
PC360LC-10 10-273
Sensor
Coolant level sensor (PC-B252-041-K-00-A)
1. Float
2. Sensor
3. Connector
4. Reservoir tank
Function (PC-B252-042-K-00-A)
• This sensor is integrated with reservoir tank, and is activated by the lowered float, if the coolant level
becomes lower than specified.
Hydraulic oil temperature sensor (PC-PMT1-041-K-00-A)
1. Connector
2. Plug
3. Thermistor
10-274 PC360LC-10
Sensor
Function (PC-PMT1-042-K-00-A)
• This sensor, installed on the suction pipe of main pump, senses the temperature variation as the change
in thermistor resistance, and outputs the corresponding signals.
Front pump oil pressure sensor (PC-C3W4-041-K-00-A)
1. O-ring
2. Sensor
3. Connector
Function (PC-C3W4-042-K-00-A)
• The sensor is installed in the control valve. It detects the delivery pressure of the front pump and outputs
variable voltage signal.
Rear pump oil pressure sensor (PC-C3W5-041-K-00-A)
1. O-ring
2. Sensor
PC360LC-10 10-275
Sensor
3. Connector
Function (PC-C3W5-042-K-00-A)
• The sensor is installed in the control valve. It detects the delivery pressure of the rear pump and outputs
variable voltage signal.
10-276 PC360LC-10
Sensor
PPC oil pressure sensor (PC-E720-041-P-00-A)
1. O-ring
2. Sensor
3. Connector
Function (PC-E720-042-P-00-A)
• PPC oil pressure sensors, 8 of which are installed to interconnect blocks in the pilot circuit between control
valves and PPC valve, and 4 of which are installed to travel PPC valves, detect the pilot pressures, and
output the corresponding variable voltage.
PC360LC-10 10-277
Sensor
Air cleaner clogging sensor (PC-A968-041-K-01-A)
1. Adapter
2. Hood
3. Indicator
4. Connector
Function (PC-A968-042-K-00-A)
• This sensor is installed on the air cleaner outlet side. The switch is turned to "ON" position, if the air
cleaner is clogged and the pressure level drops to the specified level (negative pressure).
Front pump swash plate sensor (PC-C3W9-041-K-00-A)
1. Sensor case
2. Spool
3. Lead wire
4. Connector
L: Operation stroke (9 mm)
10-278 PC360LC-10
Sensor
Function (PC300-C3W9-042-K-00-A)
• This senor, installed to the front pump of the main pump, detects the stroke of servo piston and outputs the
• The output voltages are sent to the pump controller which converts the voltages into the pump swash
plate angles (oil flow) to process them.
• The relation between oil flow of pump and output voltage is as shown in the following graph.
PC360LC-10 10-279
Sensor
Rear pump swash plate sensor (PC-C3WB-041-K-00-A)
1. Sensor case
2. Spool
3. Lead wire
4. Connector
L: Operation stroke (9 mm)
Function (PC300-C3WB-042-K-00-A)
• This senor, installed to the rear pump of the main pump, detects the stroke of servo piston and outputs the
• The output voltages are sent to the pump controller which converts the voltages into the pump swash
plate angles (oil flow) to process them.
• The relation between stroke and output voltage is shown in the graph below.
• The relation between oil flow of pump and output voltage is shown in the graph below.
10-280 PC360LC-10
Sensor
Water-in-fuel sensor (PC-AEB3-041-K-00-A)
1. Connector
2. Tube
3. Sensor
4. O-ring
Function (PC-AEB3-042-K-00-A)
• This sensor is installed to the cup of fuel prefilter.
• This sensor outputs a signal when detecting water exists in the fuel beyond the specified level.
PC360LC-10 10-281
10-282 PC360LC-10
SHOP MANUAL
HYDRAULIC EXCAVATOR
PC360LC-10
Model Serial Number
PC360LC-10 70001 and up
20 Standard value tables

4 20 Standard value tables
PC360LC-10 20-1
Table of contents

20 Standard value tables.................................................................................................................... 20-1
Standard service value table........................................................................................................ 20-3
Standard value table for engine related parts .......................................................................... 20-3
Standard value table for machine .......................................................................................... 20-5
20-2 PC360LC-10
Standard value table for engine related parts
Standard service value table (ALL-A000-001-K-00-A)
Standard value table for engine related parts (PC300_10-A000-033-K-00-A)

Engine SAA6D114E-5
Standard value Repair limit
Item Measurement conditions Unit
for new machine
High idle 2,050 ± 30 2,050 ± 30
Engine speed • Coolant temperature: 30 to Low idle rpm 1,000 ± 30 1,000 ± 30
100 °C
Rated speed 1,950 1,950
Boost • Coolant temperature: 30 to 100 °C
pressure • Hydraulic oil temperature: 45 to 55 °C kPa 167 to 207
Min. 133 {1,000}
(Aftercooler • Swing lock switch: ON {mmHg} {1,250 to 1,550}
inlet pressure) • Arm IN relief + One-touch power max. ON
Engine outlet
• Coolant temperature: 30 to (Between Bosch
100 °C turbocharger Max. 2.0 Max. 2.5
index
Exhaust gas • At relief with arm IN and KDPF
color • Swing lock switch: ON inlet)
• After kept for 5 seconds at KDPF outlet
normal condition Bosch ―
(Exhaust pipe Max. 0.5
index
outlet)
Valve • Engine coolant temperature: Intake valve 0.305 0.152 to 0.559
mm
clearance Normal temperature Exhaust valve 0.559 0.381 to 0.813
Compression • Engine oil temperature 40 to 60 °C MPa
Min. 2.6 {26.5} Min. 2.1 {21.4}
pressure • Engine speed Min. 170 rpm {kg/cm2}
• Coolant temperature: 30 to 100 °C kPa
Blowby • Hydraulic oil temperature: 45 to 55 °C {mm Max. 1.96 {200} Max. 2.94 {300}
pressure • Arm IN relief + One-touch power max. ON H2O}
• When KCCV circuit is disconnected
• Coolant temperature: 30 to Rated 0.34 to 0.59
Engine oil MPa Min. 0.21 {2.1}
100 °C horsepower {3.5 to 6.0}
pressure {kg/cm2}
• SAE15W-40 oil Low idle Min. 0.15 {1.5} Min. 0.08 {0.8}
EGR valve
and KVGT
Low idle Min. 1.2 {12.0} Min. 1.2 {12.0}
drive oil • Coolant temperature: 30 to
pressure 100 °C MPa
• Hydraulic oil temperature: 45 Oil pressure {kg/cm2}
KVGT control to 55 °C fluctuation 0.3 to 1.0 0.3 to 1.0
oil pressure range in whole {3 to 10} {3 to 10}
speed range
Engine oil
Whole speed range (inside oil pan) °C 80 to 110 Max. 120
temperature
Auto-tensioner Auto-tensioner
Fan belt ― ― (Automatic (Automatic
tension
adjustment) adjustment)
Air • Between compressor pulley and fan pulley
conditioner • Deflection when pressed with thumb at 60 N mm 13 to 15
13 to 15
compressor {6.2 kg}
belt tension
PC360LC-10 20-3
Standard value table for engine related parts

Engine SAA6D114E-5
Item Measurement conditions Unit
for new machine
High idle Min. 480 {4.9} Min. 480 {4.9}
Low-pressure
During
circuit Min. 105 {1.07} Min. 105 {1.07}
cranking
Low-pressure
circuit kPa
High idle Max. 80 {0.82} Max. 80 {0.82}
(pressure {kg/cm2}
difference)
High idle
Return circuit During Max. 18.6 {0.19} Max. 18.6 {0.19}
cranking
• Coolant
Fuel pressure temperature: Negative
30 to 100 °C pressure –27.1 to 0 –27.1 to 0
circuit (at fuel
supply {–203 to 0} {–203 to 0}
connector)
Negative kPa
High idle –33.9 to 0 –33.9 to 0
pressure {mmHg}
circuit (at {–254 to 0} {–254 to 0}
supply pump)
Fuel feed
pump outlet Min. 34 {0.35} Min. 34 {0.35}
pressure
• Coolant temperature: 30 to During
Supply pump 100 °C cranking (Min. Min. 75 Min. 75
discharge • Discharge rate for 30 150 rpm)
seconds
Low idle ml Max. 350 Max. 350
Return rate
from supply Return rate for During
pump 30 seconds cranking (Min. Max. 320 Max. 320
• Coolant 150 rpm)
temperature:
Fuel return 30 to 100 °C 60 seconds Low idle Max. 70 Max. 70
rate from During
Max. several Max. several
injector 30 seconds cranking (Min. —
drops drops
150 rpm)
Leakage from • Coolant temperature: 30 to
pressure 100 °C Low idle — Max. 30 drops Max. 30 drops
limiter • Leakage for 60 seconds
• Coolant temperature: 30 to Turn the
Delivery of
100 °C starting switch
fuel feed ml Max. 100 Max. 100
• Delivery for 10 seconds to the ON
pump
(Mean of three deliveries) position
EGR valve • Coolant temperature: 30 to
and KVGT 100 °C MPa
Low idle Min 1.2 {12.0} Min 1.2 {12.0}
valve drive oil • Hydraulic oil temperature: 45 {kg/cm2}
pressures to 55 °C
• Coolant temperature: 30 to
KVGT control 100 °C MPa 0.3 to 1.0 0.3 to 1.0
oil pressure Low idle
• Hydraulic oil temperature: 45 {kg/cm2} {3.0 to 10} {3.0 to 10}
to 55 °C
20-4 PC360LC-10
Standard value table for machine
Standard value table for machine (PC300_10-0000-033-K-00-A)

Engine speed
Item Measurement condition Unit
for new machine
• Engine coolant temperature: 30 to 100
°C
• Hydraulic oil temperature: 45 to 55 °C
Speed at 2-pump rpm 1,930 ± 100 1,930 ± 100
• Engine: high idle
relief
• Working mode: power mode (P)
• Swing lock switch OFF position
• Arm IN relief
• Engine coolant temperature: 30 to 100
°C
Speed at 2-pump • Hydraulic oil temperature: 45 to 55 °C
relief + One-touch • Engine: high idle rpm 1,800 ± 100 1,800 ± 100
power max. ON • Working mode: power mode (P)
• Arm IN relief + One-touch power
maximizing switch ON
Speed when auto-
• Auto-deceleration switch in ON rpm
deceleration is 1,000 ± 30 1,000 ± 30
position
operated
• All control levers in NEUTRAL position
Travel of control valve spool

for new machine
Boom control valve
Arm control valve
• Engine: stopped
Bucket control mm
• For measuring point, see "Control 9.5 ± 0.5 9.5 ± 0.5
valve
valve".
Swing control valve
Travel control valve
Travel of control lever

for new machine
Boom control lever 85 ± 10 85 ± 10
Arm control lever • Engine: stopped 85 ± 10 85 ± 10
Bucket control lever • At center of control 85 ± 10 85 ± 10
lever grip
Swing control lever 85 ± 10 85 ± 10
• Read value to end of mm
Travel control lever travel 115 ± 12 115 ± 12
(excluding play at Work
equipment Max. 15 Max. 20
Play of control lever NEUTRAL)
Travel Max. 20 Max. 25
PC360LC-10 20-5
Operating effort of control lever and pedal

for new machine
15.7 ± 3.9
Boom control lever Max. 24.5 {2.5}
{1.6 ± 0.4}
15.7 ± 3.9
Arm control lever Max. 24.5 {2.5}
{1.6 ± 0.4}
12.7 ± 2.9
Bucket control lever • Engine: high idle Max. 21.6 {2.2}
• Control lever: At center of grip N {1.3 ± 0.3}
• Pedal: At tip of pedal {kg} 12.7 ± 2.9
Swing control lever • Read max. value through travel end. Max. 21.6 {2.2}
{1.3 ± 0.3}
24.5 ± 5.9
Travel control lever Max. 39.2 {4.0}
{2.5 ± 0.6}
74.5 ± 18.6
Travel control pedal Max. 107.6 {11}
{7.6 ± 1.9}
20-6 PC360LC-10
Oil pressure
for new machine
• Engine: high idle MPa 3.9 ± 1.0 3.9 ± 1.0
Unload pressure • Working mode: power mode (P)
• Hydraulic pump output pressure with {kg/cm2} {40 ± 10} {40 ± 10}
all control levers in NEUTRAL position
34.81 (+1.47/-
1.18) 33.15 to 36.77
{355 (+15/-12)} {338 to 375}
RAISE
*37.26 (+1.47/- *35.6 to 39.23
1.18) {363 to 400}
Boom relief {380 (+15/-12)}
• Hydraulic oil
pressure LOWER at
temperature: 45 to 55 ° 18.13 ± 0.98 16.66 to 19.6
C low-pressure
• Engine: high idle setting {185 ± 10} {170 to 200}
• Working mode: power LOWER at 31.36 ± 1.47 29.4 to 33.32
mode (P) high-pressure
• Values marked with setting {320 ± 15} {300 to 340}
MPa
Arm relief pressure *are oil pressures
when one-touch power {kg/cm2} 34.81 (+1.47/-
1.18) 33.15 to 36.77
max. is ON (reference
only) {355 (+15/-12)} {338 to 375}
Bucket relief
• Swing only, swing lock *37.26 (+1.47/- *35.6 to 39.23
pressure
switch: ON 1.18) {363 to 400}
• Travel only, travel {380 (+15/-12)}
speed: Hi 30.87 (+1.47/-
Swing relief 28.42 to 32.85
2.45)
pressure {285 to 335}
{315 (+15/-25)}
37.27 (+2.94/-
Travel relief 35.8 to 40.7
0.98)
pressure {365 to 415}
{380 (+30/-10)}
• Engine: high idle MPa 3.23 ± 0.2 2.84 to 3.43
Control circuit oil
• Self-pressure reducing valve outlet
pressure {kg/cm 2} {33 ± 2} {29 to 35}
pressure with all control levers in
NEUTRAL position
• Hydraulic oil All control 3.9 ± 1.0 3.9 ± 1.0
temperature: 45 to 55 ° levers in
C NEUTRAL {40 ± 10} {40 ± 10}
• Working mode: power MPa
LS differential
mode (P)
pressure {kg/cm2} 2.45 ± 0.1 2.45 ± 0.1
• Travel speed: Hi Travel levers
• Run either track idle at half stroke {25 ± 1} {25 ± 1}
• LS differential pressure
= Pump pressure – LS
pressure
• Hydraulic oil OFF 0 0
Solenoid valve temperature: 45 to 55 ° (de-energized) MPa {0} {0}
output pressure C ON {kg/cm2} 2.9 2.9
• Engine: high idle (energized) {30} {30}
PC360LC-10 20-7
Swing
for new machine
Overswing deg. Max. 120 Max. 150
• Overswing of swing circle after one
turn
• For measuring posture, see "Swing 1"
• Hydraulic oil 90 deg. 3.3 ± 0.4 Max. 4.2
temperature: 45 to 55 °
C
• Working mode: power
Time required to mode (P)
sec.
start swinging • Time required to pass 180 deg. 4.7 ± 0.5 Max. 5.7
90 deg. and 180 deg.
points after starting
swing
• For measuring posture,
see "Swing 1"
Time required to • Working mode: power mode (P)
sec. 31.6 ± 0.9 Max. 38
complete turns • Time required to complete 5 turns after
one turn
• Engine: stopped
• On slope of 15 deg., set upper
structure crosswise and make
Swing drift on a
matchmarks on inner race and outer mm 0 0
slope
race of swing circle.
• Distance that matchmarks move apart
after 5 minutes
Leakage from • Engine: high idle
swing motor • Swing lock switch: ON l/min Max. 5.5 Max. 11
• Leakage in 1 minute during swing relief
20-8 PC360LC-10
Travel
for new machine
• Hydraulic oil Lo 58.0 ± 11.5 45.0 to 74.5
temperature: 45 to 55 ° Mi 41.5 ± 6.0 34.0 to 51.5
C
Travel speed (idle • Working mode: power
mode (P) sec.
running)
• Time required to make Hi 34.0 ± 2.0 32.0 to 41.5
5 idle turns of track
after 1 idle turn
see "Travel 1"
• Hydraulic oil Lo 22.5 ± 4.2 18.1 to 30.2
temperature: 45 to 55 ° Mi 16.0 ± 2.1 13.7 to 20.3
C
Travel speed • Working mode: power
mode (P) sec.
(actual running)
• Time required to travel Hi 13.1 ± 0.7 12.1 to 15.1
20 m after running up
10 m
see "Travel 2"
• Travel speed: Lo
Travel deviation • Travel deviation (X) in travel of 20 m mm Max. 200 Max. 300
after running up 10 m on firm and level
ground
• For measuring posture, see "Travel 2"
and "Travel 3"
• Engine: stopped
• Place machine on slope of 12 deg. with
Machine drift on a
sprocket on uphill side. mm 0 0
slope
• Travel distance by hydraulic drift of
travel for 5 minutes
Leakage from • Engine: high idle
• Lock sprocket with pin, etc. l/min 15 30
travel motor
• Leakage in 1 minute during travel relief
PC360LC-10 20-9
Work equipment
for new machine
Whole work
equipment
(hydraulic drift • Hydraulic oil temperature: 45 to 55 °C mm Max. 550 Max. 825
Hydraulic drift of work equipment
measured at • Level and flat ground

tooth tip) • Fill bucket with dirt or rated load
Boom cylinder (21,170 N {2,160 kg})
(Retraction • Engine: stopped
• Work equipment control lever in mm Max. 30 Max. 45
amount of
cylinder) NEUTRAL position
• Fall amount for 15 minutes as
Arm cylinder measured every 5 minutes starting
(Extension immediately after initial setting mm Max. 165 Max. 248
amount of • For measuring posture, see "Work
cylinder) equipment 1"
Bucket cylinder (Boom top horizontal, fully retracted
(Retraction arm, fully extended bucket cylinder)
mm Max. 25 Max. 38
amount of
cylinder)
• Hydraulic oil temperature: RAISE 3.7 ± 0.4 Max. 4.5
45 to 55 °C
mode (P)
Boom speed • Time required to move sec.
boom between RAISE LOWER 2.8 (+0.6/0) Max. 4.0
stroke end and ground
touch point of bucket
see "Work equipment 2"
Work equipment speed
(P)
• Hydraulic oil temperature: 3.9 ± 0.4 Max. 4.5
mode
45 to 55 °C
(E)
IN
• Engine: high idle 3.9 ± 0.4 Max. 4.5

mode
• Time required to move
Arm speed (L) sec.
arm between OUT stroke 4.9 ± 0.5 Max. 5.7
end and IN stroke end mode
OUT
(P)
see "Work equipment 3" 2.9 ± 0.3 Max. 3.5
mode
• Hydraulic oil temperature: CURL 3.2 ± 0.3 Max. 3.8
45 to 55 °C
mode (P)
Bucket speed • Time required to move sec.
bucket between DUMP DUMP 2.3 ± 0.3 Max. 2.9
stroke end and CURL
stroke end
see "Work equipment 4"
20-10 PC360LC-10
Work equipment
for new machine
• Engine: low idle
• Set boom at full RAISE position. Move
boom control lever to LOWER position.
Boom time lag Measure length of time before front of sec. Max. 4.0 Max. 4.6
machine starts lifting off the ground
after work equipment touches the
ground.
• For measuring posture, see "Work
equipment 5"
• Set arm at full OUT position. Move arm
Time lag
control lever to IN position. Measure

Arm time lag sec. Max. 4.0 Max. 4.6
length of time before arm starts moving
in IN direction again after it stops at
vertical position momentarily.
equipment 6"
• Set bucket at full DUMP position. Move
bucket control lever to CURL position.
Bucket time lag Measure length of time before bucket sec. Max. 4.0 Max. 6.0
starts moving in CURL direction again
after it stops at vertical position
momentarily.
equipment 7"
Cylinder 4.5 20
Internal oil leakage

Center swivel cc/min
• Leakage amount for 1 minute during 10 50
joint
relief of cylinder to be measured or
travel motor
PC360LC-10 20-11
Performance of combined operation

for new machine
Travel deviation in • Working mode: power mode (P)
combined • Travel speed: Lo
operation of work • Travel deviation (X) in travel of 20 m mm Max. 400 Max. 440
equipment and after running up 10 m on firm and level
travel ground
and "Travel 3"
Pump swash plate sensor

for new machine
• Hydraulic oil All control
temperature: 45 to 55 ° levers in 1.560 ± 0.20 1.560 ± 0.63
Pump swash plate C NEUTRAL
sensor output • Engine: high idle When running V
voltage • Working mode: power track idle off
mode (P) ground (lever 3.632 ± 0.20 3.632 ± 0.63
• Travel speed: Hi at stroke end)
• Run either track idle
Main pump
for new machine
• Pump speed (rpm): 1,800 rpm
• PC-EPC current value (mA): 440 mA
• Test pump delivery pressure (MPa {kg/
Main pump cm2}): P1 Q Q
performance • Delivery pressure of another pump l/min
(See graph) (See graph)
(MPa {kg/cm2}): P2
• Average delivery pressure
(MPa {kg/cm2}): Pp = (P1 + P2) / 2
a Bring pump delivery pressure (P1) and (P2) as close as possible to the average pressure when
measuring.
a Avoid measuring the near turning point of the graph because the error increases there.
a When measuring with the pump mounted on the machine, if it is impossible to set the engine speed to the
specified speed by using the fuel control dial, take the pump delivery and the engine speed at the time of
measurement, and use them as a base for calculating the pump delivery at the specified speed.
20-12 PC360LC-10
Posture of machine for measuring performance and measurement

procedure (PC300_10-0000-321-K-00-A)
Control valve: Spool travel
Swing 1: Overrun when stopping swing, time required for starting swing , time required for swing
PC360LC-10 20-13
Swing 2: Amount of Hydraulic drift of swing
20-14 PC360LC-10
Travel 1: Travel speed (idle running)
Travel 2: Travel speed (actual run), travel deviation
Travel 3: Travel deviation
Travel 4: Hydraulic drift of travel
PC360LC-10 20-15
Work equipment 1: Hydraulic drift of the work equipment
Work equipment 2: Boom speed
Work equipment 3: Arm speed
Work equipment 4: Bucket speed
20-16 PC360LC-10
Work equipment 5: Boom time lag
Work equipment 6: Arm time lag
Work equipment 7: Bucket time lag
PC360LC-10 20-17
20-18 PC360LC-10
SHOP MANUAL
HYDRAULIC EXCAVATOR
PC360LC-10
Model Serial Number
PC360LC-10 70001 and up
30 Testing and adjusting

5 30 Testing and adjusting
PC360LC-10 30-1
Table of contents

30 Testing and adjusting .................................................................................................................... 30-1
Related information on testing and adjusting ................................................................................. 30-3
Tools for testing and adjusting ............................................................................................... 30-3
Sketch of tools for testing and adjusting ................................................................................. 30-7
Testing engine speed ........................................................................................................... 30-9
Testing boost pressure ....................................................................................................... 30-10
Testing exhaust gas color ................................................................................................... 30-13
Testing and adjusting valve clearance .................................................................................. 30-15
Testing compression pressure............................................................................................. 30-19
Testing blowby pressure ..................................................................................................... 30-27
Testing engine oil pressure ................................................................................................. 30-29
Testing EGR valve and KVGT oil pressures .......................................................................... 30-30
Testing fuel pressure .......................................................................................................... 30-31
Testing fuel discharge, return and leakage............................................................................ 30-38
Bleeding air from fuel system .............................................................................................. 30-44
Testing fuel circuit for leakage ............................................................................................. 30-45
Handling cylinder cutout mode operation.............................................................................. 30-46
Handling no-injection cranking operation.............................................................................. 30-47
Checking and adjusting air conditioner compressor belt tension ............................................. 30-48
Replacing fan belt .............................................................................................................. 30-49
Replacing alternator belt ..................................................................................................... 30-50
Power train............................................................................................................................... 30-51
Testing swing circle bearing clearance ................................................................................. 30-51
Testing and adjusting track tension ...................................................................................... 30-52
Releasing remaining pressure from hydraulic circuit .............................................................. 30-53
Testing and adjusting oil pressure in work equipment, swing, and travel circuits....................... 30-54
Testing oil pressure of control circuit .................................................................................... 30-60
Testing and adjusting oil pressure in pump PC control circuit.................................................. 30-62
Testing and adjusting oil pressure in pump LS control circuit .................................................. 30-67
Testing outlet pressure of solenoid valve .............................................................................. 30-76
Testing PPC valve output pressure ...................................................................................... 30-80
Adjusting play of work equipment and swing PPC valves....................................................... 30-82
Testing pump swash plate sensor ........................................................................................ 30-83
Isolating the parts causing hydraulic drift in work equipment................................................... 30-84
Testing oil leakage ............................................................................................................. 30-86
Bleeding air from hydraulic circuit ........................................................................................ 30-88
Cab and its attachments ............................................................................................................ 30-91
Checking cab tipping stopper .............................................................................................. 30-91
Adjusting mirrors ................................................................................................................ 30-92
Electrical system ...................................................................................................................... 30-95
Special functions of machine monitor ................................................................................... 30-95
Adjusting rearview camera angle ....................................................................................... 30-161
Handling voltage circuit of engine controller........................................................................ 30-163
Handling battery disconnect switch .................................................................................... 30-164
Testing diodes ................................................................................................................. 30-165
Pm clinic ................................................................................................................................ 30-166
Pm clinic service .............................................................................................................. 30-166
30-2 PC360LC-10
Related information on testing and adjusting
Related information on testing and adjusting (ALL-3831-001-A-00-A)
Tools for testing and adjusting (PC300-5320-304-A-00-A)
Testing and Sym-

Part No. Part name Q'ty Remarks
adjusting item bol
Testing boost -101 to 200 kPa {-760 to 1,500
pressure A 799-201-2202 Boost gauge kit 1 mmHg}
1 799-201-9002 Handy smoke checker 1
Testing exhaust
gas color B Commercially Bosch index 0 to 9
2 Smoke meter 1
available
Testing and 1 795-799-1131 Gear 1
adjusting valve C Commercially
2 Feeler gauge 1
clearance available
1 795-502-1590 Compression gauge 1 0 to 7 MPa {0 to 70 kg/cm2}
2 795-799-6700 Puller 1
Testing
Adapter
compression D 3 795-790-6111 1
pressure 4 6754-11-3130 Gasket 1
Commercially Inside diameter: approx. 15 mm
5 Hose 1
available
1 799-201-1504 Blowby checker 1 0 to 5 kPa {0 to 500 mmH2O}
Testing blowby
pressure E Commercially
2 Plug 3 Hose inside diameter:24 mm
available
1 6732-61-3107 Adapter 1 Size: M10 × 1.0 mm
2 6215-81-9710 O-ring 1
799-101-5002 Hydraulic tester 1
Testing engine
F 3 799-101-5160 • Nipple 1
oil pressure
790-261-1150 • Hose 1
4 799-401-2320 • Oil pressure gauge 1 Pressure range: 1.0 MPa {10 kg/cm2}
5 790-261-1204 Digital hydraulic tester 1
1 799-401-3100 Adapter 1
2 799-401-3200 Adapter 1
Testing EGR • Nipple
799-101-5160 2 R 1/8
valve and KVGT G
oil pressures 3 799-101-5150 • Hose 1
799-261-1150 • Hose 1
799-101-5140 • Oil pressure gauge 1 Pressure range: 2.5 MPa {25 kg/cm2}
PC360LC-10 30-3
Testing and Sym-

adjusting item bol
799-101-5160 • Nipple 1
1 799-101-5150 • Hose 1
790-261-1150 • Hose 1
799-101-5140 • Oil pressure gauge 1
6732-81-3170 Adapter 2 Size: M10 × 10 o R1/8
3
Testing fuel 6215-81-9710 O-ring 1
pressure H
4 799-401-2320 Oil pressure gauge 1 Pressure range: 1.0 MPa {10 kg/cm2}
5 795-790-5110 Screw 1 Size: M12 × 1.5 mm
795-790-1500
6 or Vacuum gauge 1
799-201-1201
7 795-790-5200 Adapter kit 1
8 795-790-5010 Fitting 1
9 795-790-1150 Pressure gauge 1
1 795-790-4700 Tester kit 1
2 6164-81-5790 Joint 1
3 07206-30812 Joint bolt 1
4 6745-71-1130 Seal washer 1
Commercially Stopwatch
5 1
available
Testing fuel Commercially
Hose Inside diameter: approx. 14 mm
delivery, return J 6 available
1
and leakage Commercially
7 Measuring cylinder 1
available
Commercially Inside diameter: approx. 8 mm
8 Hose 1
available
9 795-790-6210 Fitting 1
10 In setting Adapter 1
11 795-790-6500 Adapter 1
Testing swing
Commercially Dial gauge
circle bearing K 1
available
clearance
Testing fuel Developer
circuit for Commercially
L for dye penetrant check 1
leakage available
(color checker)
Testing and 790-261-1150 • Hose 1
adjusting oil 1
Pressure range: 60 MPa {600 kg/
pressure in work 799-101-5110 • Oil pressure gauge 1 cm2}
equipment, M 2
swing, and travel 790-261-1204 Digital hydraulic tester 1
circuits 3 799-101-5220 Nipple 1 Size: M10 × 1.25 mm
4 07002-11023 O-ring 1
30-4 PC360LC-10
Testing and Sym-

adjusting item bol
1 799-101-5220 Nipple 1 Size: M10 × 1.25 mm
2 07002-11023 O-ring 1
Testing oil 799-101-5002 Hydraulic tester 1
pressure in N
control circuit 3 790-261-1150 • Hose 1
799-101-5130 • Oil pressure gauge 1 Pressure range: 6 MPa {60 kg/cm2}
1 799-101-5220 Nipple 1 Size: M10 × 1.25 mm
2 07002-11023 O-ring 1
Testing and 799-101-5002 Hydraulic tester 1
adjusting oil
790-261-1150 • Hose 1
pressure in P
pump PC control 3 Pressure range: 60 MPa {600 kg/
799-101-5110 • Oil pressure gauge 1 cm2}
circuit
796T-440-1101 Sensor adapter 1
796-440-1150 • Wiring harness 1
796T-440-1160 • Nipple 1
799-401-2350 • Washer 1
1
799-401-2340 • Coupling 1
07002-61823 • O-ring 1
Pressure range: 50 MPa {500 kg/
7861-93-1812 • Pressure sensor 1 cm2}
Testing and
adjusting oil 2 799-101-5220 Nipple 1 Size: M10 × 1.25 mm
pressure in Q
3 07002-11023 O-ring 1
pump LS control Hydraulic tester
799-101-5002 1
790-261-1150 • Hose 1
4 Pressure range: 60 MPa {600 kg/
799-101-5110 • Oil pressure gauge 1 cm2}
Differential pressure
6 799-401-2701 gauge 1
799-101-5160 • Nipple 1 R 1/8
1
790-261-1150 • Hose 1
Testing solenoid 799-101-5130 • Oil pressure gauge 1 Pressure range: 6 MPa {60 kg/cm2}
valve outlet R 2 790-261-1204 Digital hydraulic tester 1
pressure 799-401-3100 Adapter 1 02 size
3
02896-11008 O-ring 1
799-401-3200 Adapter 1 03 size
4
02896-11009 O-ring 1
799-101-5160 • Nipple 1 R 1/8
1
790-261-1150 • Hose 1
Testing PPC 799-101-5130 • Oil pressure gauge 1 Pressure range: 6 MPa {60 kg/cm2}
valve output S 2 790-261-1204 Digital hydraulic tester 1
pressure 799-401-3100 Adapter 1 02 size
3
02896-11008 O-ring 1
799-401-3200 Adapter 1 03 size
4
02896-11009 O-ring 1
PC360LC-10 30-5
Testing and Sym-

adjusting item bol
Testing oil Commercially Measuring cylinder
leakage T 1
available
Testing coolant
temperature and — 799-101-1502 Digital thermometer 1 -99.9 to 1,299 °C
oil temperature
Testing ― 79A-264-0021 Push-pull scale 1 0 to 294 N {0 to 30 kg}
operating effort
and depressing ― 79A-264-0091 Push-pull scale 1 0 to 490 N {0 to 50 kg}
effort
Testing stroke
and hydraulic ― Commercially Ruler 1
available
drift
Testing work
equipment ― Commercially Stopwatch 1
speed available
Testing voltage ― Commercially Multimeter 1
and resistance available
Removal and
installation of
charge (boost) 3.26 mm Torx wrench
― Commercially Torx wrench 1
pressure and available (KTC Q4T15 or equivalent)
temperature
sensors
Removal and
installation of
― 795-799-6210 Socket 1 27 mm deep socket
engine oil
pressure switch
Removal and
installation of 19 mm deep socket
coolant ― 795T-981-1010 Socket 1
temperature (MITOLOY 4ML-19 or equivalent)
sensor
30-6 PC360LC-10
Sketch of tools for testing and adjusting (PC300-3531-061-A-00-A)
Note) Komatsu will not be held responsible for special tools manufactured according to these sketches.
F1, N1, P1, Q1: Sensor adapter
F1, N1, P1, Q1: Nipple
PC360LC-10 30-7
Note) Komatsu will not be held responsible for special tools manufactured according to these sketches.
—: Socket
30-8 PC360LC-10
Engine and cooling system
Testing engine speed (PC300-A000-360-K-00-A)
a Check the engine speed by using the 4) Operate the left work equipment control lever
troubleshooting support or monitoring function of to relieve the arm circuit at the IN stroke end
the machine monitor. and test the engine speed.
5. Testing speed (around rated speed) at 2-
a Measure the engine speed under the following
pump relief + one-touch power maximizing
conditions.
function
• Coolant temperature: 30 to 100 °C
1) Start the engine and operate the arm cylinder
to “arm IN” stroke end.
Testing (PC220-A000-388-K-00-A) 2) Set the fuel control dial to the high idle (MAX)
position and set the working mode to the
1. Preparation work
Power mode (P).
Operate the machine monitor so that the engine
3) While operating the left work equipment
speed can be monitored.
control lever to relieve the arm circuit at “arm
a For the operating method of the machine IN” stroke end and pressing the one-touch
monitor, see "Special functions of machine power maximizing switch, test the engine
monitor". speed.
a Monitoring code: 01002 "Engine speed" a The one-touch power maximizing function is
reset automatically in approximately 8.5
seconds even if the switch is kept pressed.
Accordingly, test the engine speed in that
period.
a You may check with the swing lock switch
ON (In this case, you do not need to operate
the one-touch power maximizing switch.)
6. Testing auto-deceleration speed
1) Start the engine, set the fuel control dial to
high idle position (MAX), and turn the auto-
deceleration function ON.
2) Set all the control levers and pedals for work
equipment, swing, and travel to the neutral
2. Testing low idle speed position and measure the engine speed
1) Start the engine and set the fuel control dial when the auto-deceleration operates.
to the low idle (MIN) position.
2) Set all the control levers and pedals for work a The engine speed lowers to a certain level
equipment, swing, and travel to the neutral approximately 5 seconds after all the levers
position and test the engine speed. and pedals are set to NEUTRAL position.
3. Testing high idle speed This level is the auto-deceleration speed.
1) Start the engine and set the fuel control dial
to the high idle (MAX) position.
2) Set the working mode in the Power Mode (P)
and set the auto-deceleration to OFF.
3) Set the swing lock switch to ON position.
4) Set all the control levers and pedals for work
equipment, swing, and travel to the neutral
position and test the engine speed.
4. Testing 2-pump relief speed
1) Start the engine and operate the arm cylinder
to “arm IN” stroke end.
2) Set the swing lock switch to OFF position.
3) Set the fuel control dial to the high idle (MAX)
position and set the working mode to the
Power mode (P).
PC360LC-10 30-9
Testing boost pressure (PC300-A900-360-K-01-A)
a Testing tools
Sym-
Part No. Part Name
bol
A 799-201-2202 Boost gauge kit
k Park the machine on a level ground and

lower the work equipment to the ground.
a Test the boost pressure under the following

condition.
• Swing lock switch ON 2. Install nipple [1] of boost gauge kit A and
• Arm IN relief + One-touch power max. connect them to gauge [2].
Testing (PC300-A900-362-K-00-A)
Measuring with machine monitor
Testing of boost pressure is available from the
troubleshooting support or monitoring function of
the machine monitor.
a For the operating method of the machine monitor,
see “Special functions of machine monitor”.
a The boost pressure is normal when it is within
the standard value range. For standard values,
see "Standard value table", "Standard value
table related to engine".
a Monitoring code: 36500 "Charge pressure-A" 3. Run the engine at middle or higher speed and
bleed oil from the hose.
a Insert the hose connector into the gauge
halfway to open the self-seal on the hose
side repeatedly, and the oil will be purged.
a If Pm kit (A) is available, you may use the air
bleeding coupling (790-261-1130) in that kit.
a If oil is left in the hose, the gauge does not
work. Accordingly, be sure to purge the oil.
4. Set the working mode to the power mode (P)
and turn the swing lock switch ON.
a If the swing lock switch is turned to ON
position, the main relief valve is set for high-
Testing by use of testing tools pressure relief.
1. Open the engine hood and remove boost 5. Measure the boost pressure when the hydraulic
pressure pickup plug (1). relief is made by arm IN operation + one-touch
power max. with engine at high idle.
a The boost pressure is normal when it is
within the standard value range. For
standard values, see "Standard value table",
"Standard value table related to engine".
30-10 PC360LC-10
2. Loosen bolt (4) fixing lock plate (3), lower lock

plate (3) and release the lock.
a Just loosen bolt (4). It is not necessary to
remove.
6. After finishing test remove the testing tools and

return the removed parts.
3 Pickup plug (1):
15 ± 2 Nm {1.53 ± 0.2 kgm}
3. Pull stay (1) to your side, hold handgrip (4-1)
How to fully open engine hood (PC300-H540-100-K- and push the engine hood backward.
01-A)
a Stay (1) comes off lock position (2) when you
a The engine hood can be opened by
pull it to your side.
approximately 90 deg. at the maximum. Open
the engine hood according to the following
procedure and lock it securely after its full
opening.
• The figure shows the engine hood which is
opened to the maximum of 90 deg.
1. Open the engine hood and fix stay (1) at the lock
position (2).
a For details, see "Operation and Maintenance
Manual".
4. After pushing the engine hood fully backward, fix

stay (1) securely at lock position (5).
PC360LC-10 30-11
a When closing the engine hood, return lock

plate (3) to the original position and tighten
fixing bolt (4).
30-12 PC360LC-10
Testing exhaust gas color (PC300-A900-360-K-02-A)
a Testing tools 2) Insert the exhaust gas intake pipe in port (3)
Sym- for the removed plug.
Part No. Part Name 3) Start the engine and absorb the exhaust gas
bol
1 799-201-9002 Handy smoke checker to the filter paper by operating the handle of
B Commercially smoke checker B1 when hydraulic relief is
2 Smoke meter made by arm IN operation at engine high
available
idle.
lower the work equipment to the ground. a Sucking time: 1.4 ± 0.2 sec.
k Be careful not to touch any hot part when

removing or installing the testing tools.
k After KDPF regeneration is started, high-

temperature exhaust gas spurts from the
inspection port, potentially causing burn
injury. Therefore, you must stop KDPF
regeneration from the machine monitor
before starting the inspection. (For the
stopping procedure of KDPF regeneration,
see the Operation and Maintenance Manual.)
a Test the exhaust gas color under the following 4) Remove the filter paper and compare it with
conditions. the attached scale for judgement.
• Coolant temperature: 30 to 100 °C 5) After finishing test remove the testing tools
• At relief with arm IN and return the removed parts.
• Swing lock switch ON 3. Measuring by using smoke meter B2
1) Connect the probe hose, accelerator switch
a If an air source and an electric power source are outlet and air hose to smoke meter B2.
not available in the field, use handy smoke
checker B1. When recording official data, etc., a Air supply pressure must be 1.5 MPa {15
use smoke meter B2. kg/cm2} or lower.
2) Connect the power cable to an AC 100 V
Testing (PC300-A900-385-K-00-A)
receptacle.
1. Open the engine hood and remove plug (1).
a Check that the smoke meter power switch
3 Plug: is in OFF position, before connecting the
51.0 to 85.3 Nm {5.2 to 8.7 kgm} power cable to the receptacle.
3) Insert probe [1] of the smoke meter B2 into
2 Plug: port (3) for the removed plug.
Seizure prevention compound (LC-G)
a When measuring at the tail pipe of KDPF

2. Measuring by using handy smoke checker B1
1) Stock a sheet of filter paper to smoke
checker B1.
PC360LC-10 30-13
4) Loosen the cap nut of the suction pump and

place the filter paper.
a Place the filter paper securely so that the
exhaust gas does not leak.
5) Turn the power switch of smoke meter B2 to
ON position.
6) Start the engine and absorb the exhaust gas

to the filter paper by depressing the
accelerator pedal of smoke meter B2 when
hydraulic relief is made by the arm IN
operation.
7) Put the polluted filter paper on non-polluted
filter paper (more than 10 sheets) in the filter
paper holder, and read the indicated value.
8) After finishing test remove the testing tools
and return the removed parts.
30-14 PC360LC-10
Testing and adjusting valve clearance (ALL-A700-001-K-00-A)
a Testing tools
Sym-
Part No. Part Name
bol
1 795-799-1131 Gear
C Commercially Feeler gauge
2
available

k Turn the battery disconnect switch to OFF

position and remove the key.
a Test and adjust the valve clearance under the 3. Remove brackets (5) (3 places) fastened
following condition. together to the head cover.
• Coolant temperature: Normal temperature
Testing (PC300-A700-361-K-00-A)
1. Open the engine hood, and remove step (1) and

frame (2).
a For opening the engine hood fully, see
"Procedure for opening engine hood fully".
4. Disconnect hoses (6) and (7), and connectors

(8) and (9).
a Hose (6): Oil pressure circuit to drive KVGT
a Hose (7): KVGT control hydraulic circuit
a Connector (8): KVGT position sensor (SVGT)
a Connector (9): KVGT speed sensor (VGT
2. Remove EGR orifice temperature sensor (3) to REV)
protect it from damaging.
a Be sure to release lock (4) before removing
EGR orifice temperature sensor (3).
5. In order to secure the space necessary to

remove the head cover, remove bracket (9) (4
bolts) and bracket (10) (1 bolt) and move wiring
harness (11) and connector box (12) from the
current positions.
PC360LC-10 30-15
6. After removing hose (13), remove breather box

a A bushing is attached to the head cover
(14) (2 bolts).
mounting bolt. Don't lose the bushing.
a Care must be used in handling the stud bolt
used in the location where the wiring harness
and bracket are fastened.
10.Remove cap (18) of the front gear cover.
7. In order to secure the space necessary to

remove the head cover, remove clamps (16) (2
places) fixing tube (15) and move tube (15) from
the current position.
11.Set the No. 1 cylinder to the compression top

dead center.
1) Remove cap (19) of the flywheel housing,
then insert gear C1 and rotate the crankshaft
in the normal direction.
a Turning gear C1 counterclockwise turns
the crankshaft in the normal direction.
8. Remove head cover mounting bolts (8 bolts).

9. Tilt and pass the head cover through bellows
pipe to remove.
2) After aligning TDC stamp line (a) of the front

gear cover with stamp line (b) of the supply
pump gear, set No.1 piston to the
compression top dead center.
30-16 PC360LC-10
a When of No. 1 cylinder is at the

compression top dead center, the rocker
arm can be manually moved as much as
the valve clearance. If the rocker arm
cannot be moved, the No. 1 cylinder is
not at its compression top dead center. In
that case, rotate the crankshaft one more
turn.
a Since the gear ratio between the supply
pump gear and crank gear is 2 : 1, 1/2
turns of the supply pump gear correspond
to 1 turn of the crank gear.
14.After finishing test, remove the testing tools and

restore the machine.
a Be sure to remove gear C1.
a Replace the gasket of the head cover with a
new one.
3 Hose (6):
15 ± 1 Nm {1.53 ± 0.10 kgm}
3 Hose (7):
25 ± 1.5 Nm {2.55 ± 0.15 kgm}
12.While the No. 1 cylinder is at the compression 3 Cylinder head cover mounting bolt:
top dead center, check the valve clearances 12 ± 2 Nm {1.22 ± 0.2 kgm}
marked with qin the following figure.
13.Then, rotate the crankshaft 1 turn in the normal 3 Mounting bolt for breather box (14):
direction and check the valve clearance of the 10 ± 2 Nm {1.02 ± 0.2 kgm}
remaining valves marked Q.
Adjustment (PC300-A700-27D-K-00-A)
a It is also allowed to check the valve
clearance of No. 1 cylinder while the piston is After testing, adjust the valve clearance according
at the compression top dead center, and then to the following procedure, if necessary.
check the valve clearance of other cylinders 1. While fixing adjustment screw (11), loosen lock
in the firing order by turning the crankshaft nut (10).
120 deg. at a time. 2. Insert feeler gauge C2 in the clearance between
rocker arm (8) and crosshead (9) and adjust the
a The valve clearance is normal when it is valve clearance with adjustment screw (11).
standard values, see "Standard value table", a With feeler gauge C2 inserted, turn and
"Standard value table related to engine". adjust adjustment screw (11) to a degree that
you can move feeler gauge C2 lightly.
a If you can move the rocker arm of air intake
valves (IN) with hand by the distance of the a The valve clearance is normal when it is
valve clearance, adjust the valves marked within the standard value range. For
with Q in the valve arrangement drawing. standard values, see "Standard value table",
a If you can move the rocker arm of exhaust 3. While fixing adjustment screw (11), tighten lock
valves (EX) with hand by the distance of the nut (10).
valve clearance, adjust the valves marked
with q in the valve arrangement drawing. 3 Lock nut (10):
a Firing order: 1-5-3-6-2-4 24 ± 4 Nm {2.45 ± 0.41 kgm}
a After tightening lock nut (10), check the valve
clearance again.
PC360LC-10 30-17
4. After finishing test, remove the testing tools and

a Be sure to remove gear C1.
a Replace the gasket of the head cover with a
new one.
3 Hose (6):
15 ± 1 Nm {1.53 ± 0.10 kgm}
3 Hose (7):
25 ± 1.5 Nm {2.55 ± 0.15 kgm}
3 Cylinder head cover mounting bolt:
12 ± 2 Nm {1.22 ± 0.2 kgm}
3 Mounting bolt for breather box (14):
10 ± 2 Nm {1.02 ± 0.2 kgm}
30-18 PC360LC-10
Testing compression pressure (PC300-A000-001-K-02-A)
a Testing tools a When measuring the compression pressure,

Sym- the fuel spurts out of the disconnected part
Part No. Part name on the common rail side. So install hose D5
bol
1 795-502-1590 Compression gauge to drain the fuel to a container.
2 795-799-6700 Puller a Do not bend the high-pressure pipe for use.
3 795-790-6111 Adapter
D
4 6754-11-3130 Gasket
Commercially Hose (inside diameter:
5 approx. 15 mm)
available
k Place the machine on a level ground and

k Turn the battery disconnect switch to OFF

position and remove the key.
k When testing the compression pressure,

take care not to get yourself burned by
touching the exhaust manifold or KDPF, or 4. Loosen injector terminal nut (4) to remove the
get caught in a rotating part. terminal from injector (9).
5. Remove the mounting bolts of rocker arm
a Measure the compression pressure under the
assembly (5) on the exhaust side, then remove
following conditions.
rocker arm assembly (5).
• Engine oil temperature: 40 to 60 °C
Testing (PC300-A000-36B-K-00-A)
1. Remove the cylinder head cover and set the

piston in the cylinder to be tested to the
compression top dead center. For details, see
"Measuring and adjusting valve clearance".
a When the piston is at the compression top
dead center, check that the intake side and
exhaust side rocker arms for the cylinder can
be moved by the amount of the valve
clearance with your fingers.
2. Remove brackets (1).
6. Remove retaining nut (6) and remove inlet
connector (7).
7. Remove holder (8).
3. After removing fuel spray prevention cap (2),

remove the sleeve nut and disconnect high-
pressure pipe (3).
a For reinstallation of the high-pressure pipe
and injection pipe, see "High-pressure pipe
and injection pipe reinstallation procedure."
PC360LC-10 30-19
12.Adjust the valve clearances.

a See "Measuring and adjusting valve
clearance".
8. Remove injector (9).

a Remove injector (9) with the impacts of the
slide hammer by using puller D2.
13.Connect hoses (10) and (11), connectors (12)
a Do not pry the top of injector (9) to remove.
and (13), and sensor (14).
a Hose (10): Oil pressure circuit to drive KVGT
a Hose (11): KVGT control hydraulic circuit
a Connector (12): KVGT speed sensor (VGT
REV)
a Connector (13): KVGT position sensor
(SVGT)
a Sensor (14): EGR orifice temperature sensor
9. Install gasket D4 to the tip of adapter D3 and

insert them into the injector mounting portion.
14.Connect gauge assembly D1 to adapter D3.

a If thin film of engine oil is applied to the
connection of gauge assembly D1 and
adapter D3, air will not leak easily.
10.Fix adapter D3 with mounting holders (8) for the

injector.
a Tighten the mounting bolts of holder (8)
alternately.
3 Holder (8) mounting bolt:
9.8 ± 2.0 Nm {1.0 ± 0.2 kgm}
11.Install rocker arm assembly (5).
3 Rocker arm assembly (5) mounting
bolt:
64.7 ± 4.9 Nm {6.6 ± 0.5 kgm}
30-20 PC360LC-10
15.Select the "no injection cranking mode" by a Push in the O-ring until it is fitted and click
operating the machine monitor. is felt.
4) Check inlet connector (7) for the following
a Turn the battery disconnect switch to ON
items. If anything wrong is found, replace it.
position, and then turn the starting switch to
ON position. 1] When burrs or wear is found in the inlet
connector top-end (a) and rear-end (b)
a To select the "No injection cranking" mode, portions.
see "Special functions of machine monitor". 2] When foreign matters are found in the
edge filter at rear-end (c) of the inlet
connector.
3] Cracks or deterioration are recognizable
on the O-ring of the inlet connector upper
(d) portion.
16.Rotate the crankshaft by the starting motor and

measure the compression pressure.
a Read the pressure when the gauge pointer is
stabilized.
a The compression pressure is normal when it 4] There is a worn part or an uneven seat
is within the standard value range. For contact mark on sealing face (e) at the
standard values, see "Standard value table", front end of the inlet connector.
17.After finishing the test, remove the testing tools a If high-pressure fuel leaks through the
and restore the machine. inlet connector, the seal face has fine
streaks or cracks.
a Install the injector and high-pressure pipe
according to the following procedure.
1) Install the injector to the cylinder head while
facing its fuel inlet hole to the air intake
manifold.
a Join protrusion (a) with holder notch (b)
before setting the injector to the cylinder
head.
5) Apply engine oil to the O-ring of inlet

connector (7) and the head side.
2 O-ring and head side of inlet
connector (7)
Engine oil (EO10W30)
6) Fasten inlet connector (7) temporarily with
retaining nut (6).
2) Tighten holder mounting bolt by 3 to 4
threads.
3) Set inlet connector (7).
PC360LC-10 30-21
a Permanent tightening follows this

temporary tightening. Be sure to tighten
each of them to the specified torque.
Insufficient or excessive tightening torque
can be the cause for fuel leakage into the
engine.
a Install the inlet connector in such that the
positioning ball of inlet connector (7)
comes to the guide groove on the
cylinder head side.
3 Retaining nut (6) (tightening
lightly):
15 ± 5 Nm {1.53 ± 0.51 kgm}
7) Tighten mounting bolts for holder (8)
alternately.
3 Holder (8) mounting bolt (19):
10 ± 2.0 Nm {1.0 ± 0.2 kgm}
8) Tighten retaining nut (6) of inlet connector
(7).
3 Retaining nut (6) (tightening to the
specified torque):
50 ± 4 Nm {5 ± 0.4 kgm}
a Apply caulking material (e) to retaining
nut (6) and the cylinder head (shaded 9) Tighten the sleeve nut for high-pressure pipe
portion). (3) in the order of cylinder head side and
2 Caulking material: common rail (10) side.
GE TOSHIBA SILICONES 3 Sleeve nut:
TOSSEAL381 37 ± 4 Nm {3.77 ± 0.41 kgm}
a For reinstallation of the high-pressure 10)Install fuel spray prevention cap (1).
pipe and injection pipe, see "High- a When installing the fuel spray prevention
pressure pipe and injection pipe cap, face the slits of the one on the
reinstallation procedure." injector side downward and of the one on
the common rail side to the other side to
the cylinder block.
a The fuel spray prevention cap is installed
to prevent fire hazards by blocking fuel
from being sprayed directly to the hot part
of the engine, should fuel leakage occur.
11)Install rocker arm assembly (5).
3 Rocker arm assembly (5) mounting
bolt:
64.7 ± 4.9 Nm {6.6 ± 0.5 kgm}
12)Adjust the valve clearances.
• See "Measuring and adjusting valve
clearance".
13)Tighten injector terminal nut (4).
3 Terminal nut (4):
2 ± 0.25 Nm {0.2 ± 0.03 kgm}
a Check that the injector wiring harness
does not interfere with the rocker arm.
30-22 PC360LC-10
a When installing the fuel spray prevention cap,

face the slits of the one on the injector side
downward and of the one on the common rail
side to the other side to the cylinder block.
a The fuel spray prevention cap is installed to
prevent fire hazards by blocking fuel from being
sprayed directly to the hot part of the engine,
should fuel leakage occur.
High-pressure pipe and injection pipe

reinstallation procedure (when replacing a high-
pressure pipe or common rail)
14)Install the cylinder head cover. a Remove all the high-pressure pipes and
injection pipes at a time.
3 Cylinder head cover mounting nut:
1. Fasten inlet connector (1) by use of retaining nut
12 ± 2 Nm {1.22 ± 0.2 kgm}
(2) with the specified torque .
On handling of high-pressure pipe, injection 3 Retaining nut (2):
pipe and fuel hose
50 ± 4 Nm {5 ± 0.4 kgm}
k Internal parts of the fuel hose mount must be 2. When installing common rail (3), loosen 3
replaced with new ones since they may be mounting bolts (4) to (6) once, then finger-
damaged when the fuel hose is removed. tighten them temporarily.
k Do not bend the high-pressure pipe or

injection pipe for use.
k Be sure to use the genuine clamp for the

high-pressure pipe and injection pipe, and
observe the specified tightening torque.
k Provide 10 mm minimum clearance between

the installed high-pressure pipe and injection
pipe, and the wiring harnesses respectively.
a If the following defects are found on the taper of

the connection of the high-pressure pipe or 3. Install high-pressure pipe assembly (7) between
injection pipe, the high-pressure pipe or injection the supply pump and common rail, then tighten
pipe must be replaced with a new one. the sleeve nuts on the supply pump side and
1. The ones which have visually recognizable common rail side to the specified torque.
longitudinal slits (b) or spots (c) in the area
a Width across flats of sleeve nut
within 2 mm from the tip (a).
2. The ones on which fingernail is caught by a Supply pump side: 19 mm
level difference that develops on the taper Common rail side: 22 mm
seal end within 2 mm from the tip (d) due to
3 Sleeve nut:
fatigue.
37 ± 4 Nm {3.7 ± 0.4 kgm}
PC360LC-10 30-23
4. Install injection pipes (8) to (13) between the

common rail and each cylinder inlet connector,
then tighten the sleeve nuts on the inlet
connector side and common rail side to the
specified torque.
Inlet connector side: 19 mm
Common rail side: 22 mm
3 Sleeve nut:
37 ± 4 Nm {3.7 ± 0.4 kgm}
5. Tighten 3 common rail mounting bolts (4) to (6)
to the specified torque. 7. Tighten sandwich clamp (19) to the specified
torque.
3 Mounting bolt:
43 ± 4 Nm {4.4 ± 0.4 kgm} 3 Mounting bolt (19):
6 Nm {0.6 kgm}

reinstallation procedure (when replacing an
injection pipe)
a Remove all the high-pressure pipes and
injection pipes once.
1. Fasten inlet connector (1) by tightening retaining
nut (2) to the specified torque.
3 Retaining nut (2):
50 ± 4 Nm {5 ± 0.4 kgm}
2. When installing common rail (3), loosen 3
6. Tighten the brackets of the sandwich clamps, mounting bolts (4) to (6) once, then finger-
that fix the high-pressure pipe and injection pipe, tighten them temporarily.
to the specified torque.
a Install the bracket for #2 injection pipe to the
location above the bracket for the high-
pressure pipe and fasten it with bolt (16).
3 Mounting bolts (14) to (18):
24 ± 4 Nm {2.4 ± 0.4 kgm}
30-24 PC360LC-10
3. Install injection pipes (7) to (12) between the

common rail and each cylinder inlet connector,
then tighten the sleeve nuts on the inlet
connector side and common rail side to the
specified torque.
3 Sleeve nut:
37 ± 4 Nm {3.7 ± 0.4 kgm}
4. Tighten 3 common rail mounting bolts (4) to (6)
to the specified torque. 6. Fasten sandwich clamp (19) by tightening the
bolt to the specified torque.
3 Mounting bolt:
3 Mounting bolt (19):
43 ± 4 Nm {4.4 ± 0.4 kgm}
6 Nm {0.6 kgm}

reinstallation procedure (when reusing the high-
pressure or injection pipe without replacing it)
1. Install high-pressure pipe assembly (7) between
the supply pump and common rail, then tighten
the sleeve nuts on the supply pump side and
common rail side to the specified torque.
Supply pump side: 19mm
5. Tighten the bolts for the brackets of the 3 Sleeve nut:

sandwich clamps, that fix the high-pressure pipe 37 ± 4 Nm {3.7 ± 0.4 kgm}
and injection pipe, to the specified torque.
a Install the bracket for #2 injection pipe to the
location above the bracket for the high-
pressure pipe and fasten it with bolt (16).
24 ± 4 Nm {2.4 ± 0.4 kgm}
2. Tighten sleeve nuts for the injection pipes (8) to

(13) between the common rail and each cylinder
inlet connector and sleeve nuts on the common
rail side to the specified torque.
3 Sleeve nut:
37 ± 4 Nm {3.7 ± 0.4 kgm}
PC360LC-10 30-25
3. Loosen all the sandwich clamps for the injection

pipe.
4. Tighten the mounting bolts for brackets (14) to
(18) for the sandwich clamp to the specified
torque.
24 ± 4 Nm {2.4 ± 0.4 kgm}
5. Fasten sandwich clamp (19) by tightening the

bolt to the specified torque.
6 Nm {0.6 kgm}
30-26 PC360LC-10
Testing blowby pressure (PC300-A000-001-K-03-A)
a Testing tools 3 Clamp:

Sym- 4.4 ± 0.5 Nm {0.45 ± 0.05 kgm}
Part No. Part Name
bol
1 799-201-1504 Blowby checker
E Commercially Plug (Hose inside
2 diameter: 24 mm)
available

a Test the blowby pressure under the following

conditions.
Testing (PC300-A000-36C-K-00-A)
1. Open the engine hood and remove crank case

pressure sensor (1).
a Be sure to release lock (2) before removing
crank case pressure sensor (1).
4. After installing crankcase pressure sensor (1),

start the engine and set the work equipment
mode to power mode (P), and turn the swing
lock switch to ON position.
a Turn the battery disconnect switch to ON
position, and then turn the starting switch to
ON position.
a If the swing lock switch is turned to ON
position, the main relief valve is set for high-
pressure relief.
5. Measure the blowby pressure when the
hydraulic relief is made by arm IN operation at
engine high idle.
a Read the gauge for blowby pressure when
the pointer is stabilized.
a The blowby pressure is normal when it is
2. Disconnect hose (3) on the outlet side of KCCV,
then plug hose (3) and KCCV tube by using
plugs E2.
3 Clamp:
4.4 ± 0.5 Nm {0.45 ± 0.05 kgm}
3. After disconnecting hose (4) on the inlet side of
KCCV, plug the tube of KCCV to which the hose
is connected by using plug E2, install tool &
adapter [1] of blowby checker E1 to hose (4),
and then connect gauge [2].
PC360LC-10 30-27

30-28 PC360LC-10
Testing engine oil pressure (PC300-AB00-001-K-00-A)
a Testing tools 4. Measure the oil pressures when the engine runs
Sym- at rated horsepower speed and low idle.
Part No. Part name
bol a The engine oil pressure is normal when it is
1 6732-61-3107 Adapter (M10 × 1.0 mm) within the standard value range. For
2 6215-81-9710 O-ring standard values, see "Standard value table",
799-101-5002 Hydraulic tester "Standard value table related to engine".
3 799-101-5160 • Nipple
F
790-261-1150 • Hose
• Oil pressure gauge
4 799-401-2320 (1.0 MPa {10 kg/cm2})
5 790-261-1204 Digital hydraulic tester

a Measure the compression pressure under the

following conditions.
Testing (PC300-AB00-362-K-00-A) 5. After finishing test, remove the testing tools and
1. Remove oil pressure pickup plug (2) at the restore the machine.
bottom of engine controller wiring harness (1).
2. After Installing adapter F1, install nipple [1] and

hose [2] in hydraulic tester F3, then connect
them to oil pressure gauge F4.
a The nipple and hose for digital hydraulic
tester F3 can also be used.
3. Start the engine and turn the auto-decelerator

OFF.
PC360LC-10 30-29
Testing EGR valve and KVGT oil pressures (PC300-A9K1-001-K-00-A)
a Testing tools 3. Install adapters G1 and G2, and then install

Sym- nipple [1] and hose [2] of hydraulic tester G3 and
Part No. Part name connect them to gauge [4].
bol
1 799-401-3100 Adapter 3 Adapter G1:
2 799-401-3200 Adapter 15 ± 1.0 Nm {1.53 ± 0.10 kgm}
799-101-5002 Hydraulic tester
799-101-5160 • Nipple (R1/8) 3 Adapter G2:
G 799-101-5150 • Hose 25 ± 1.5 Nm {2.55 ± 0.15 kgm}
3
790-261-1150 • Hose a Use gauge [4] of 2.5 MPa {25 kg/cm2}.
• Pressure gauge (2.5
799-101-5140 MPa {25 kg/cm2}) a The nipple and hose for digital hydraulic
4 790-261-1204 Digital hydraulic tester tester G4 can also be used.


a The standard value for the EGR valve drive oil
pressure and the KVGT drive oil pressure are
the same, because they share the same circuit.
Testing (PC300-A9K1-362-K-00-A)
1. Open the engine hood and remove step (1).

4. Start the engine and measure the oil pressure at
low idle.
a The EGR valve and KVGT oil pressure is
normal when it is within the standard value
range. For standard values, see "Standard
value table", "Standard value table related to
engine".
2. Disconnect hoses (2) and (3).

• Hose (2): EGR valve and KVGT drive
hydraulic circuit
• Hose (3): KVGT control hydraulic circuit

3 Hose (2):
15 ± 1.0 Nm {1.53 ± 0.10 kgm}
3 Hose (3):
25 ± 1.5 Nm {2.55 ± 0.15 kgm}
30-30 PC360LC-10
Testing fuel pressure (PC300-AE20-001-K-00-A)
a Testing tools
Sym-
Part No. Part name
bol
799-101-5160 • Nipple
1 799-101-5150 • Hose
790-261-1150 • Hose
799-101-5140 • Oil pressure gauge
Adapter (M10 × 10 o R1/
6732-81-3170 8)
3
H 6215-81-9710 O-ring
Oil pressure gauge (1.0
4 799-401-2320 MPa {10 kg/cm2})
5 795-790-5110 Screw (M12 × 1.5)
795-790-1500
6 or Vacuum gauge
799-201-1201
7 795-790-5200 Adapter kit
8 795-790-5010 Fitting
9 795-790-1150 Pressure gauge
k When removing or installing testing tools for

the fuel system, stop the engine and wait for
at least 30 seconds until the remaining
pressure is released from the fuel circuit. (Do
not start the work immediately after the
engine is stopped since remaining pressure
is still in the circuit.)

a Measure only the fuel pressure in the low-

pressure circuit from the feed pump through the
main fuel filter to the supply pump, and in the
return circuit between the supply pump/common
rail/ injector and fuel tank.
k Since the pressure in the high-pressure
circuit from the supply pump through the
common rail to the injector is very high and
dangerous, do not measure it.
a Measure the fuel pressure under the following

conditions.
PC360LC-10 30-31
A: Low-pressure circuit testing position (main fuel filter inlet side)

B: Low-pressure circuit testing position (main fuel filter outlet side)
C: Return circuit testing position (supply pump drain port)
D: Negative pressure circuit testing position (fuel supply connector)
E: Negative pressure circuit testing position (supply pump)
F: Fuel feed pump outlet pressure testing position (supply pump)
30-32 PC360LC-10
Testing (PC300-AE20-362-K-00-A)
Testing low-pressure circuit (main fuel filter inlet
side)
1. Open the side cover on the right side of the
machine and remove fuel pressure pickup plug
(1) on the main fuel filter inlet side.
4. After finishing the test, remove the testing tools

and restore the machine.
3 Fuel pressure pickup plug (1):
20 to 22 Nm {2.0 to 2.2 kgm}
Testing low-pressure circuit (pressure

difference)
2. After installing adapter H3, install nipple [1] and
1. Remove fuel pressure pickup plug (1) at the
hose [2] of hydraulic tester H1, and connect
main fuel filter inlet side and fuel pressure pickup
them to oil pressure gauge H4.
plug (2) on the outlet side.
a When installing adapters H3, be sure to
install the O-ring.
3 Adapter H3:
20 to 22 Nm {2.0 to 2.2 kgm}
a The nipple and hose of digital hydraulic tester
H2 can also be used.
2. After installing adapter H3 to each of the

inspection holes on the inlet and outlet sides,
install nipple [1] and hose [2] in hydraulic tester
H1, and connect them to oil pressure gauge H4.
a When installing adapters H3, be sure to
install the O-ring.
3. Start the engine and measure the pressure in 3 Adapter H3:
the low-pressure circuit with the engine at high 20 to 22 Nm {2.0 to 2.2 kgm}
idle.
a If the engine cannot be started, you can H2 can also be used.
measure the fuel pressure while rotating the
engine using the starting motor. However, to
protect the starting motor, do not rotate the
engine for more than 20 seconds
continuously.
a The pressure in the low-pressure circuit (on
the main fuel filter inlet side) is normal when
it is within the standard value range. For
PC360LC-10 30-33
Testing return circuit

1. Remove pipe (1) between the air cleaner and
KVGT.
3. Start the engine and measure the pressure on

the inlet side and outlet side of the low-pressure
circuit with the engine at high idle.
a If the engine cannot be started, you can 2. Remove brackets (2).
continuously.
3. Remove joint bolt (3) from the fuel return hose of

the supply pump.
4. Calculate the pressure difference in the low-

pressure circuit.
a Pressure difference in low-pressure circuit =
Pressure on main fuel filter inlet side -
Pressure on main fuel filter outlet side
a The pressure in the low-pressure circuit
(pressure difference) is normal when it is
4. In place of joint bolt (3), install screw H5 and
nipple [1] and hose [2] in hydraulic tester H1,
a If the pressure is higher than the criteria, the and then connect them to oil pressure gauge [3].
main fuel filter may be clogged. In this case,
a When installing screw H5, be sure to install
replace the main fuel filter and measure
the seal washer.
again.
5. After finishing test, remove the testing tools and 3 Screw H5:
restore the machine. 36 ± 5 Nm {3.6 ± 0.5 kgm}
3 Fuel pressure pickup plugs (1), (2): a Use oil pressure gauge [3] of 2.5 MPa {25 kg/
20 to 22 Nm {2.0 to 2.2 kgm} cm2} capacity.
H2 can also be used.
30-34 PC360LC-10
5. After installing pipe (1) between the air cleaner

and KVGT, start the engine and measure the
pressure in the return circuit with the engine at
high idle.
a If the engine cannot be started, you can
continuously.
a The pressure in the return circuit is normal
when it is within the standard value range.
For standard values, see "Standard value 2. Connect adapter H3 and fuel vacuum gauge H6.
table", "Standard value table related to
engine". a When installing adapters H3, be sure to
install the O-ring.

restore the machine. 3. Start the engine and measure the pressure in
the negative pressure circuit with the engine at
3 Joint bolt (3): high idle.
36 ± 5Nm {3.6 ± 0.5 kgm}
a The pressure in the negative pressure circuit
Testing the negative pressure circuit (at fuel (at fuel supply connector) is normal when it is
supply connector) within the standard value range. For
1. Remove fuel pressure pickup plug (1) of the fuel standard values, see "Standard value table",
supply connector. "Standard value table related to engine".
a If the pressure is higher than the standard
value, the fuel pre-filter may be clogged. In
this case, replace the fuel pre-filter and
measure the pressure again.
PC360LC-10 30-35
3 Fuel pressure pickup plug (1): 3 Intake hose clamp:

20 to 22 Nm {2.0 to 2.2 kgm} 10.5 ± 0.5 Nm {107 ± 5 kgcm}
Testing the negative pressure circuit (at supply Testing fuel feed pump outlet pressure (at
pump) supply pump)
1. Disconnect fuel tube (1) from supply pump (2). 1. The measuring position is the same as that used
2. Remove fitting (3) mounted to supply pump (2). for the fuel negative pressure circuit pressure
test (at supply pump). However, only gauge H9
is used for the testing tool.
3. Install hose assembly [1] of adapter kit H7 to

fitting H8, and install them to supply pump (2).
3 Fitting H8: 2. Operate fuel feed pump (10) by turning the
24 ± 4 Nm {2.4 ± 0.4 kgm} starting switch to the ON position and measure
4. Reconnect fuel tube (1). the pressure at the fuel feed pump outlet.
5. Connect vacuum gauge H6 to hose assembly a Reference: Fuel feed pump (10) is installed
[1]. to cooling plate (12) on the back of engine
controller (11).
6. Start the engine and measure the pressure in

the negative pressure circuit with the engine at
high idle. a The fuel feed pump operates for 60 seconds
after the starting switch is turned to the ON
a The pressure in the negative pressure circuit position, then stops. So measure the
(at supply pump) is normal when it is within pressure while the pump is in operation.
the standard value range. For standard
values, see "Standard value table", a The outlet pressure of the fuel feed pump is
"Standard value table related to engine". normal when it is within the standard value
7. After finishing the test, remove the testing tools range. For standard values, see "Standard
and restore the machine. value table", "Standard value table related to
engine".
3 Fitting (3):
24 ± 4 Nm {2.4 ± 0.4 kgm}
• Replace fuel tube (1) with a new one at
reassembly.
30-36 PC360LC-10
a If the outlet pressure of the electric fuel feed

pump deviates from the standard value,
check the following points.
• Check that fuel is fed to the fuel feed
pump.
• When fuel is not fed to the fuel supply
pump, which can happen immediately
after the replacement of the fuel filter or
removal or installation of a fuel system
part, operate the fuel feed pump three to
four times by using the starting switch to
bleed air from the fuel circuit. Then, after
making sure that fuel is fed, measure the
pressure again.
• If the outlet pressure of the fuel feed
pump does not fall in the standard value
when fuel is fed to it, remove check valve
(13) of engine controller cooling plate (12)
to check it for sticking.

3 Fuel pressure pickup plug (2):
20 to 22 Nm {2.0 to 2.2 kgm}
PC360LC-10 30-37
Testing fuel discharge, return and leakage (PC300-AE20-001-K-01-A)
a Testing tools k Place the machine on a level ground and

Sym- lower the work equipment to the ground.
Part No. Part name
bol
a Since some fuel flows out during test, prepare a
1795-790-4700 Tester kit
container of approximately 20 l.
26164-81-5790 Joint
307206-30812 Joint bolt k When removing or installing testing tools for
46745-71-1130 Seal washer the fuel system, stop the engine and wait for
Commercially at least 30 seconds until the remaining
5 Stopwatch
available pressure is released from the fuel circuit. (Do
Commercially Hose (inside diameter: not start the work immediately after the
6 approx. 14 mm)
J available engine is stopped since remaining pressure
Commercially Measuring cylinder is still in the circuit.)
7
available
Commercially Hose (inside diameter:
8 approx. 8 mm)
available
9 795-790-6210 Fitting
10 795-790-5600 Adapter
11 795-790-6500 Adapter
A: Measuring position of discharge from supply pump

B: Measuring position of return rate from supply pump
C: Measuring position of return rate from injector
D: Measuring position of leakage from pressure limiter
E: Measuring position of discharge from fuel feed pump
30-38 PC360LC-10
Testing (PC300-AE20-363-K-00-A)
Testing supply pump discharge
1. Remove the fuse for the electric fuel feed pump.
a This stops the pump operation when the
engine starting switch is turned to ON
position.
KVGT.

and KVGT, crank the engine for 30 seconds and
measure the discharge by using measuring
cylinder J7.
a Do not crank the engine for longer than 20
seconds to protect the starting motor. In the
measurement, repeat the steps of "cranking
of 15 seconds, 15 seconds of rest and
cranking of 15 seconds."
4. Remove fuel spray prevention cap (3) and a The supply pump discharge is normal when it
remove the high-pressure pipe (4). is within the standard value range. For
5. Install hose J6 to the connector on the discharge

side of the supply pump.
a Clamp hose J6 by using a hose band to 7. After finishing test, remove the testing tools and
prevent it from coming off. restore the machine.
a Adjust the route of hose J6 so that it does not

sag and put its end in the oil pan.
PC360LC-10 30-39
3 High-pressure pipe (4) mounting 3 Joint bolt J3:

sleeve nut: 24 ± 4 Nm {2.45 ± 0.41 kgm}
37 ± 4 Nm {3.7 ± 0.4 kgm} 6. Install hose J8 to joint J2.
Testing supply pump return rate

KVGT.

and KVGT, start the engine and measure the
fuel return rate for 30 seconds with the engine
running at low idle by using measuring cylinder
2. Remove brackets (2). J7.
continuously. In the measurement, repeat the
steps of "cranking of 15 seconds, 15
seconds of rest and cranking of 15 seconds."
3. Remove joint bolt (3) from the fuel return hose of

the supply pump.
a The supply pump return rate is normal when

it is within the standard value range. For
4. Install cap nut [1] of tester kit J1 to fuel return

hose (4) to prevent outflow of fuel.
a When installing cap nut [1], be sure to install
the seal washer.
5. Install joint J2 to the supply pump by using joint
bolt J3.
a When installing joint J2 and joint bolt J3, be
sure to install the seal washer.
30-40 PC360LC-10
5. Start the engine and measure the fuel leakage

rate for 60 seconds with the engine running at
low idle by using measuring cylinder J7.
3 Fuel return hose (4) mounting joint
a The leakage from pressure limiter is normal
bolt (3):
24 ± 4 Nm {2.45 ± 0.41 kgm} For standard values, see "Standard value
Testing leakage from pressure limiter
engine".
a If failure code [CA599] or [CA2249] is displayed, 6. After finishing test, remove the testing tools and
perform troubleshooting for it first. restore the machine.
1. Remove joint bolt (1) of the pressure limiter and 3 Spill tube (2) mounting joint bolt (1):
disconnect spill tube (2).
24 ± 4 Nm {2.45 ± 0.41 kgm}
Measuring return rate from injector

1. Remove check valve (1) on the cylinder head
and disconnect spill tube (2).
2. Install cap nut [1] of tester kit J1 to spill tube (2)

to prevent outflow of fuel.
a When installing cap nut [1], be sure to install
the seal washer.
3. Install joint J2 to the pressure limiter with joint 2. Install cap nut [1] of tester kit J1 to spill tube (2)
bolt J3. to prevent outflow of fuel.
a When installing joint J2 and joint bolt J3, be a When installing cap nut [1], be sure to install
sure to install the seal washer. the seal washer.
3. Install joint J2 to the cylinder head with joint bolt
3 Joint bolt J3: J3.
24 ± 4 Nm {2.45 ± 0.41 kgm}
a When installing joint J2, be sure to install the
4. Install hose J8 to joint J2.
seal washer.
3 Joint bolt J3:
24 ± 4 Nm {2.45 ± 0.41 kgm}
4. Install hose J8 to joint J2.
PC360LC-10 30-41
3 Spill tube (2) attaching check valve

(1):
24 ± 4 Nm {2.45 ± 0.41 kgm}
Testing discharge of fuel feed pump

The fuel feed pump operates for 60 seconds after
the starting switch is turned to ON position, then
stops. So complete the measurement of discharge
within 60 seconds.
KVGT.
5. Start the engine and measure the fuel return rate

in 60 seconds by using measuring cylinder J7
with the engine at low idle.
continuously. In the measurement, repeat the
steps of "cranking of 15 seconds, 15
seconds of rest and cranking of 15 seconds."
a The return rate from injector is normal when it 3. Remove the connector of the supply pump and
is within the standard value range. For install fitting J9.
standard values, see "Standard value table", 4. Install adapter kit J10 to fitting J9 and connect
"Standard value table related to engine". the fuel tube again.
5. Install adapter J11 and insert it into measuring
cylinder J7.

30-42 PC360LC-10
6. Turn the starting switch to ON position to

operate the fuel feed pump.
7. When the fuel starts to flow out continuously,
measure the discharge for 10 seconds by using
measuring cylinder J7.
8. Repeat the measurement of step 7 3 times and

calculate the mean.
a Discharge of the fuel feed pump is normal
For standard values, see "Standard value
engine".
PC360LC-10 30-43
Bleeding air from fuel system (ALL-AD00-001-K-00-A)
a If fuel is used up or if a fuel circuit part is

removed and installed, bleed air from the fuel
circuit according to the following procedure.
Bleeding air (PC300-AD00-231-K-01-A)
1. Fill the fuel tank up with fuel.

a Fill the fuel until the fuel level monitor
reaches the green range.
(Confirm with the fuel level monitor after
turning the starting switch to ON.)
machine.
3. Loosen and pull out hand primer (1) and move it
back and forth.
a Continue the above operation until the
operation of hand primer (1) becomes heavy.
a You may not remove the plug on the top
surface of the main fuel filter.
4. After the air bleeding, push in and tighten hand

primer (1).
30-44 PC360LC-10
Testing fuel circuit for leakage (ALL-AD00-001-K-01-A)
a Testing tools 9. Stop the engine and check the fuel piping and
Sym- devices for fuel leakage.
Part No. Part Name
bol a Check the high-pressure circuit for fuel
Developer for dye leakage focusing on the area to which color
Commercially penetrant check (color
L checker L is sprayed.
available checker)
a If any fuel leakage is detected, repair it and
k Very high pressure is generated in the high- perform inspection again from Step 1.
pressure circuit of the fuel system. If fuel
leaks while the engine is running, it presents a If no fuel leakage is detected, inspection is
a serious danger that could result in a fire. completed.
After checking the fuel system or removing
its parts, check it for fuel leakage according
to the following procedure.

a Clean and degrease the engine and the parts

around it in advance so that you can find easily
fuel leakage.
Testing (PC-AD00-364-K-00-A)
1. Spray color checker (developer) L to the fuel

supply pump, common rail, fuel injectors, and
joints of the high-pressure fuel piping.
2. Start the engine, keep its speed at 1,000 rpm or
below, and stop it when its speed is stabilized.
3. Stop the engine and check the fuel piping and
devices for fuel leakage.
a Check the high-pressure circuit for fuel
leakage focusing on the area to which color
checker L is sprayed.
perform inspection again from Step 1.
4. Start the engine and keep it running at low idle.
6. Start the engine and keep it running at high idle.
8. Run the engine at high idle, then load it.
a Relieve the arm circuit at the IN stroke end.
PC360LC-10 30-45
Handling cylinder cutout mode operation (PC400-AD00-34F-K-00-A)
a The cylinder cut-out test mode operation means

to run the engine with the fuel injectors of one or
more cylinders disabled electrically to reduce the
number of active cylinders. The purposes and
effects of this operation are as follows.
1. This mode is used to find out a cylinder which
does not output power properly (or, combustion
in it is abnormal).
2. When a cylinder is selected for the Cylinder Cut-
out Mode operation, if the engine speed and
output do not change from the normal operation
(all-cylinder operation), that cylinder has one or
more defects.
The following problems can be considered:
• Compression leak from cylinder head gasket
• Defective injection from injector
• Defective piston, piston ring or cylinder liner
• Defective valve mechanism (valve operating
system)
• Defective electrical system
3. The injector of each cylinder is separately
controlled electronically in the common rail fuel
injection system, so the cylinder cut-out test can
be performed easily by the simple operations of
the switches compared with the mechanical fuel
injection system. This allows to find out a
defective cylinder easily.
30-46 PC360LC-10
Handling no-injection cranking operation (PC-A000-25L-K-00-A)
a No-injection cranking means to crank the engine

by using the starting motor while all the
injections are stopped electrically. The purpose
and effect of this operation are as follows.
No-injection cranking is performed to lubricate
the engine parts and to protect them from
seizure. It is performed before the engine is
started, or after the machine has been stored for
a long period.
a When performing no-injection cranking operation,
see "Special functions of machine monitor".
PC360LC-10 30-47
Checking and adjusting air conditioner compressor belt tension (ALL-K5A0-001-

K-00-A)
k Park the machine on a level ground and a When the V-belt is replaced, check and
lower the work equipment to the ground. adjust the tension again after operating the
machine for 1 hour.
Testing (PC300-K5A0-285-K-01-A)
a After tightening the bolts, check the belt
1. Open the engine hood and remove fan guard tension again according to the above
(1). procedure.
2. Press the intermediate point of the belt between 4. After finishing adjustment, restore the machine.
fan pulley and compressor pulley with a finger
and measure deflection (a) of the belt.
• Belt depressing force: 60 N {6.2 kg}
• Belt deflection: 13 to 15 mm
3. After finishing test, restore the machine.

Adjusting (PC300-K5A0-27C-K-01-A)
a If the belt deflection is improper, adjust it

1. Loosen mounting bolt (2) and fixing bolt (3) of
bracket (1).
2. Slide bracket (1) by using the bar, adjust the belt
tension and then tighten fixing bolt (3).
3. Tighten mounting bolts (2) of bracket (1).
a Check each pulley for breakage, wear of the
V-groove, and contact of the V-belt with V-
groove.
a If the V-belt is elongated exceeding the
adjustment allowance or it has a cut or a
crack, replace it with a new one.
30-48 PC360LC-10
Replacing fan belt (ALL-B430-001-K-00-A)
a The auto-tensioner is provided for the fan belt.

Thus, testing and adjustment of the belt is
usually not necessary.
a Disconnect the air conditioner compressor belt
before replacing the fan belt.
Replacing (PC300-B430-923-K-00-A)
1. Open the engine hood and remove fan guard (1)

and fan belt guard (2).
3. Replace fan belt (3).
• Check each pulley for breakage and crack.
2. Insert wrench (a) to the portion (A) (width across

flats: 12.7 mm) of tensioner assembly (4), and
rotate it toward the rear of the machine to
decrease the fan belt (3) tension.
k Firmly set wrench (a) on tensioner

assembly (4) at portion (A) before
applying turning force to the wrench. (The
spring of tensioner assembly (4) is strong.
If the wrench is loosely inserted and
rotated, wrench (a) can accidentally come
off and this is extremely dangerous.)
k After removing fan belt (3), slowly and

carefully restore tensioner assembly (4).
k Be careful not to get your fingers caught

between the pulley and fan belt (3) during
work.
PC360LC-10 30-49
Replacing alternator belt (PC400-AKM4-001-K-00-A)
a The auto-tensioner is provided for the alternator

belt. Thus, checking and adjusting of the belt is
usually not necessary.
a Remove air conditioner compressor belt before
replacing the alternator belt.
Replacing (PC300-AKM4-923-K-00-A)
1. Open the engine hood and remove fan guard (1)

and fan belt guard (2).
2. Insert wrench (b) to the portion (B) (width across 3. Replace alternator belt (3).
flats: 12.7 mm) of tensioner assembly (4), and • Check each pulley for breakage and crack.
rotate it toward the rear of the machine to
decrease the alternator belt (3) tension.
k Firmly set wrench (b) on tensioner

assembly (4) at portion (B) before
spring of tensioner assembly (4) is strong.
If the wrench is loosely inserted and
rotated, wrench (b) can accidentally come
off and this is extremely dangerous.)
k After removing the alternator belt (3),

slowly and carefully restore tensioner
assembly (4).

between the pulley and alternator belt (3)
during work.
30-50 PC360LC-10
Power train
Power train (ALL-C100-001-K-30-A)
Testing swing circle bearing clearance (ALL-J117-001-K-00-A)
a Testing tools 5. From this state, read the dial gauge K value.
Sym- a The value indicated by dial gauge K is the
Part No. Part Name
bol clearance of the bearing.
Commercially Dial gauge
K
available
k Be careful not to put a hand or foot under the

undercarriage, while taking measurement.
Testing (PC-J117-365-K-00-A)
1. Fasten dial gauge K to swing circle outer race

(1) or inner race (2), and touch the probe to the
end surface of inner race (2) or outer race (1) on
the opposite side.
a Set dial gauge K in the front side or rear side
of the machine.
6. Return the machine to the condition of step 2
and check that dial gauge K indicates 0 point.
a If 0 value is not indicated, repeat the steps 3
through 5.
2. Set the work equipment to the maximum reach

posture and set the bucket tip to the height of the
underside of the revolving frame.
a At this time, the front side of the upper
structure rises and the rear side lowers.
3. Set the reading of dial gauge K to the 0 point.
4. Set the arm almost perpendicular to the ground

and lower the boom until the front part of the
tracks float by 150 to 200 mm.
a At this time the front of the upper structure
rises and the rear lowers.
PC360LC-10 30-51
Undercarriage and frame
Testing and adjusting track tension (ALL-DTL0-001-K-00-A)
Testing (PC220-DTL0-285-K-00-A) a You can add grease until dimension (b)

between the idler guide and the track
1. Run the engine at low idle and move the
machine forward by the length of track on frame end becomes 0 mm. If the tension
is still low, the pins and bushings will
ground, and then stop slowly.
become excessively worn. In this case,
2. Place square bar [1] on the track shoes between
turn 180 deg. , or replace the pins and
the idler and the 1st carrier roller.
bushings.
a As the square bar [1], use an angle steel, etc.
which deflects less.
3. Measure maximum clearance (a) between steel
bar [1] and track shoe.
• Standard maximum clearance (a): 10 to 30
mm
2. Decreasing tension
1) Loosen valve (2) to discharge grease, and
then tighten it.
k Do not loosen the valve more than 1

turn. Otherwise, the valve jumps out
Adjusting (PC220-DTL0-27C-K-00-A) because of the high-pressure grease
inside.
a If the track tension is improper, adjust it
according to the following procedure. 2) To check that the tension is proper, run the
1. Increasing tension engine at low idle and move the machine
forward by the length of track on ground,
1) Add grease through grease fitting (1) by
then stop slowly.
using a grease gun.
3) After adjusting, check the track tension again
2) To check that the tension is proper, run the
according to the above procedure.
engine at low idle and move the machine
forward by the length of track on ground,
then stop slowly.
3) After adjusting, check the track tension again
according to the above procedure.
30-52 PC360LC-10
Hydraulic system
Releasing remaining pressure from hydraulic circuit (ALL-C000-001-P-02-A)
Releasing remaining pressure (PC300- a The engine does not start unless the lock
C000-22A-K-00-A) lever is set to LOCK position.
1. Releasing remaining pressure from hydraulic 4) Repeat above steps 2) and 3) 2 to 3 times,
tank and all remaining pressure is released from
the piping completely.
k The hydraulic tank is airtight and 3. Releasing remaining pressure from swing motor
pressurized, so release the remaining circuit
pressure from it when removing a hose or a The remaining pressure in the swing motor
a plug connected to it. circuit can be released by performing the
1) Lower the work equipment to the ground in a same operation as that described in
stable posture and stop the engine. "Releasing remaining pressure in hydraulic
2) Loosen oil filler cap (1) of the hydraulic tank cylinder circuit" (Operate the lever to SWING
gradually to release the air in the tank. only, however).
4. Releasing remaining pressure from travel motor
circuit
a The control valve spool of the travel motor
circuit is open circuit, so the remaining
pressure in the circuit can be released by
performing the same operation as that
described in "Releasing remaining pressure
in hydraulic tank".
2. Releasing remaining pressure from hydraulic

cylinder circuit
k When disconnecting a pipe between a

hydraulic cylinder and the control valve,
release the remaining pressure from the
piping according to the following
procedure.
1) Release the remaining pressure in the
hydraulic tank. For details, see "Releasing
remaining pressure in hydraulic tank".
a Leave the oil filler cap of the hydraulic
tank removed.
2) Turn the starting switch to ON position and
set the work equipment lock lever to FREE
position, and then operate the right and left
work equipment control levers forward and
backward, and to the right and left.
a The control valve is operated by the
pressure in the accumulator. The
pressure in the accumulator is used up,
however, after the work equipment
control levers are operated 2 to 3 times.
3) Start the engine and run it at low idle for 10
seconds to raise the pressure in the
accumulator.
PC360LC-10 30-53
Hydraulic system
Testing and adjusting oil pressure in work equipment, swing, and travel
circuits (PC300-C000-001-K-01-A)
a Testing tools
Sym-
Part No. Part name
bol
790-261-1150 • Hose
1
• Pressure gauge (60
799-101-5110 MPa {600 kg/cm2})
M
3 799-101-5220 Nipple (M10 x 1.25 mm)
4 07002-11023 O-ring

2. Increase the hydraulic oil temperature to 45 to
Then, release the remaining pressure from
55°C and measure the pump delivery pressure.
the hydraulic system. For details, see
"Releasing remaining pressure from Measuring method by using oil pressure gauge
hydraulic system". 1. Open the side cover on the left side of the
machine and remove oil pressure pickup plugs
a Measure the oil pressure in the work equipment, (1) and (2) of the main pump.
swing, and travel circuits under the following
condition. • (1): Front pump delivery pressure pickup port
(rear of machine)
• Hydraulic oil temperature: 45 to 55 °C • (2): Rear pump delivery pressure pickup port
Testing (PC300-C000-362-K-00-A) (front of machine)
a The oil pressure in the work equipment, swing,
and travel circuits (pump delivery pressure) can
be checked from the "Monitoring Pre-defined" or
"Monitoring" screen of the machine monitor.
Measuring method by using machine monitor

1. Start the engine and set the machine monitor to
"Monitoring/Pre-defined" or "Monitoring" screen.
a For the setting method, see "Special
functions of machine monitor".
• Monitoring code: 01100 "F Pump Pressure"
• Monitoring code: 01101 "R Pump Pressure"
• "Monitoring/Pre-defined (8/14)" screen
• "Monitoring" screen
30-54 PC360LC-10
Hydraulic system
2. Install nipple M3 and connect oil pressure gauge

[3] and hose [2] of hydraulic tester M1. Combination of pump, actuator, and valve
a Use an oil pressure gauge of 60 MPa {600 a When the oil flow from the pumps is divided, the
kg/cm2}. front pump and rear pump actuate each actuator
independently as shown in the following table.
a When installing nipple M3, be sure to install Note that the relieved valve varies depending on
O-ring M4. the actuator.
a The nipple and hose of digital hydraulic tester a When the work equipment circuit or swing circuit
M2 can also be used. is relieved singly, the oil of the pumps are
merged. When the travel circuit is relieved singly,
the oil of the pumps are divided.
a The actuators in the table are arranged in the
order when the control valve is viewed from the
front of the machine. (With service valve of 1
attachment specification)
Pump
Actuator Valve relieved
(Unload valve) F unload valve

Attachment Safety valve
Front pump
Boom Hi Arm Hi F main relief valve

Bucket F main relief valve
L.H. travel F main relief valve
RAISE: F main relief valve
Boom Lo
LOWER: Safety valve
Swing Swing motor safety valve
Rear pump
R.H. travel R main relief valve

Arm Lo R main relief valve
(Unload valve) R unload valve
Measuring unload pressure

1. Start the engine, set the working mode to Power
Mode (P), and turn the auto-decelerator OFF.
3. Start the engine and increase the hydraulic oil 2. Set all control levers and pedals to the
temperature to 45 to 55°C. Read oil pressure NEUTRAL and measure the oil pressure while
gauge [3]. running the engine at high idle.
a Hydraulic oil pressure when the unload valve
unloads is displayed.
Measuring work equipment relief pressure

1. Start the engine and set the working mode to
Power Mode (P).
PC360LC-10 30-55
Hydraulic system
2. Run the engine at high idle and operate the

cylinder to be measured to the stroke end.
3. Measure the oil pressure when the cylinder is
relieved.
a Except when the boom LOWER is selected,
the pressure at which the main relief valve is
relieved is displayed.
a Except when the boom LOWER is selected,
if the one touch power maximizing switch is
not pressed, the main relief valve is relieved
at low pressure. If this switch is pressed, the
valve is relieved at high pressure.
2. Set the working mode to Power Mode (P).
a Except when the boom LOWER is selected, 3. Measure the pressure when the engine is
keep the swing lock switch in OFF position running at high idle and the travel circuit is
during the measurement. If it is moved to ON relieved.
position, the 2-stage relief valve stays always
at ON position and the valve is relieved at k Before operating the travel lever (pedal),
high pressure. check the pin position and locked
direction of the travel again.
a When the boom LOWER is selected, the
pressure at which the safety valve was a The pressure at the time when the main relief
relieved is displayed. valve is relieved is displayed. The travel
circuit is always relieved at high pressure.
a The relief pressure for the boom LOWER is
lower than the main relief pressure. Work after finishing measurement
a When the boom LOWER is selected, if the After finishing test, remove the testing tools and
machine push-up switch is turned OFF, the restore the machine.
valve is relieved at low pressure. If this Adjusting (PC300-C000-270-K-00-A)
switch is turned ON, the valve is relieved at
a The unload valve cannot be adjusted.
high pressure.
Adjusting work equipment and travel relief
Measuring swing relief pressure pressure
1. Start the engine, set the working mode to the
Power Mode (P), and turn the swing lock switch a When the relief pressure of the work equipment
ON. circuit or travel circuit is abnormal, adjust main
2. Measure hydraulic oil pressure when the engine relief valves (3) and (4) according to the
is running at high idle and the swing circuit is following procedure.
relieved. • (3): Main relief valve for front pump circuit
• (4): Main relief valve for rear pump circuit
a Hydraulic oil pressure when the swing motor
safety valve is relieved is displayed. a Adjust only the low relief pressure of the main
relief valve. When the low relief pressure is
a The swing motor relief pressure is lower than
adjusted, the high relief pressure is set
that of the main relief valve.
automatically.
Measuring travel relief pressure a The low relief pressure is the pressure under the
1. Start the engine and lock the travel mechanism. following condition: the 2-stage relief solenoid
valve is not energized and the pilot pressure is
k Insert pin [2] between the sprocket and not applied to the selector port.
the track frame to securely lock the track.
30-56 PC360LC-10
Hydraulic system
a The high-pressure relief pressure mode denotes

the state in which the machine push-up switch is
turned on, disabling to apply the pilot pressure to
the selector port.
1. Disconnect the pilot hose.

2. While fixing pressure adjustment screw (5),
loosen locknut (6).
3. Turn adjustment screw (5) to adjust the
pressure.
a When pressure adjustment screw (5) is: 2. While fixing pressure adjustment screw (9),
• turned clockwise, the pressure is loosen locknut (8).
increased. 3. Turn adjustment screw (9) to adjust the
• turned counterclockwise, the pressure is pressure.
decreased. a When pressure adjustment screw (9) is:
a Pressure of adjustment per turn of pressure • turned clockwise, the pressure is
adjustment screw (5): increased.
Approximately 20.5 MPa {approximately 209 • turned counterclockwise, the pressure is
kg/cm2} decreased.
4. While fixing pressure adjustment screw (5), a Pressure of adjustment per turn of pressure
tighten locknut (6). adjustment screw (9):
3 Lock nut (6): Approximately 21.8 MPa {approximately. 222
49 to 58.8 Nm {5 to 6 kgm} kg/cm2}
tighten locknut (8).
3 Lock nut (8):
93 to 123 Nm {9.5 to 12.5 kgm}
5. Connect the pilot hose.

6. After finishing adjustment, check the oil pressure
again according to the above measuring
procedure.
Adjusting boom LOWER relief pressure (on the 5. Connect the pilot hose.
side where high pressure is set) 6. After finishing adjustment, check the oil pressure
a If the high-pressure relief pressure for boom procedure.
LOWER is improper, adjust the high pressure
set side of 2-stage suction-safety valve (7) for
boom LOWER according to the following
procedure.
PC360LC-10 30-57
Hydraulic system
Adjusting boom LOWER relief pressure (on the 5. Connect the pilot hose.
side where low pressure is set) 6. After finishing adjustment, check the oil pressure
a If the low-pressure relief pressure for boom again according to the above measuring
LOWER is improper or when the high pressure procedure.
set side is adjusted, adjust the low pressure set Adjusting swing relief pressure
side of 2-stage suction-safety valve (7) for boom
LOWER according to the following procedure. a If the swing relief pressure is improper, adjust
swing 2-stage relief valve (12) according to the
a The low-pressure relief pressure mode denotes following procedure.
the state in which the machine push-up switch is
turned off, disabling to apply the pilot pressure to
the selector port.

loosen locknut (13).
1. Disconnect the pilot hose. 3. Turn adjustment screw (14) to adjust the
2. While fixing pressure adjustment screw (11), pressure.
loosen locknut (10).
a When pressure adjustment screw (14) is:
pressure. • turned clockwise, the pressure is
increased.
a When pressure adjustment screw (11) is: • turned counterclockwise, the pressure is
• turned clockwise, the pressure is decreased.
increased.
a Pressure of adjustment per turn of pressure
• turned counterclockwise, the pressure is
adjustment screw (14):
decreased.
7.68 MPa {78.3 kg/cm2}
a Pressure of adjustment per turn of pressure 4. While fixing pressure adjustment screw (14),
adjustment screw (11): tighten locknut (13).
Approximately 21.8 MPa {approximately 222
3 Lock nut (13):
kg/cm2}
4. While fixing pressure adjustment screw (11), 93.1 to 122.5 Nm {9.5 to 12.5 kgm}
tighten locknut (10).
3 Lock nut (10):
78 to 93 Nm {8.0 to 9.5 kgm}
5. Connect the pilot hose.
30-58 PC360LC-10
Hydraulic system
6. After finishing adjustment, check the oil pressure

procedure.
PC360LC-10 30-59
Hydraulic system
Testing oil pressure of control circuit (PC300-C010-001-K-00-A)
a Testing tools a When installing nipple N1, be sure to install

Sym- O-ring N2.
Part No. Part name
bol a The nipple and hose of digital hydraulic tester
1 799-101-5220 Nipple (M10 × 1.25 mm) N4 can also be used.
2 07002-11023 O-ring
N 790-261-1150 • Hose
3
799-101-5130 MPa {60 kg/cm2})
k Lower the work equipment to the ground and

stop the engine. Operate the control levers
several times to release the remaining
pressure in the piping, and then loosen the
oil filler cap of the hydraulic tank slowly to
release the pressure in the hydraulic tank.
a Measure the control circuit oil pressure under

the following condition.
Testing (PC300-C010-362-K-00-A)
1. Remove oil pressure pickup plug (1) of the

control valve.
3. Start the engine and keep it running until the

hydraulic oil temperature increases to 45 to 55 °
C.
4. Measure the hydraulic oil pressure, when the
engine is running at high idle and all the control
levers are set to NEUTRAL.

2. Install nipple N1 and connect hose [2] and oil a Do not adjust the relief valve for the control
pressure gauge [3] of hydraulic tester N3. circuit oil pressure.
a Use an oil pressure gauge of 6 MPa {60 kg/ a The control circuit oil pressure may be
cm2}. measured with oil pressure pickup plug (2) of
the main pump (at rear of machine).
30-60 PC360LC-10
Hydraulic system
PC360LC-10 30-61
Hydraulic system
Testing and adjusting oil pressure in pump PC control circuit (PC300-C2A3-001-K-

00-A)
a Testing tools
Sym-
Part No. Part name
bol
1 799-101-5220 Nipple (M10 × 1.25 mm)
2 07002-11023 O-ring
790-261-1150 • Hose
P • Pressure gauge (60
3 799-101-5110 MPa {600 kg/cm2})
799-101-5130 MPa {60 kg/cm2})
2. Install nipple P1 to each pressure pickup port.
stop the engine. Operate the control levers a When installing nipple P1, be sure to install
several times to release the remaining O-ring P2.
pressure in the piping, and then loosen the 3. Connect hose [2] and oil pressure gauge [3] of
oil filler cap of the hydraulic tank slowly to hydraulic tester P3 to front control pressure
release the pressure in the hydraulic tank. pickup port (3).
a Before measuring the oil pressure in the pump a Use an oil pressure gauge of 60 MPa {600
PC control circuit, check that the oil pressure in kg/cm2}.
the work equipment, swing, and travel circuits a The nipple and hose of digital hydraulic tester
and the oil pressure of the control circuit are P4 can also be used.
proper.
a Measure the PC valve output pressure (servo
piston inlet pressure) under the following
conditions.
Testing (PC300-C2A3-362-K-00-A)
Measuring PC valve output pressure (servo
piston inlet pressure)
a To measure the PC valve output pressure (servo
piston inlet pressure), measure the front and
rear pump delivery pressures simultaneously
and compare them.
a Front pump delivery pressure and rear pump
delivery pressure can be checked on the
"Monitoring/Pre-defined" or "Monitoring" screen
of the machine monitor.
1. Remove oil pressure pickup plugs (3) and (4) of
the main pump.
• (3): Front control pressure pickup port
• (4): Rear control pressure pickup port

55 °C.
5. Measure the pump delivery pressure and PC
valve output pressure (servo piston inlet
pressure) at the same time after setting the
30-62 PC360LC-10
Hydraulic system
machine to the following conditions with the

engine running at high idle.
• Swing lock switch: ON
(Turning 2-stage relief ON switches to high-
pressure relief)
• Work equipment: Arm IN relief
a Judgment method:
When the ratio of the pump discharge
pressure to the PC valve output pressure
(servo piston inlet pressure) reaches the
following value, those pressures are normal.
Oil pressure to be Oil pressure ratio
measured
Front pump delivery
pressure 1
Front PC valve output
Approx. 0.6 (approx. 3/5)
pressure
a If the PC valve or the servo piston is

defective, the PC valve output pressure
(servo piston inlet pressure) comes to the
same pressure as the pump delivery
pressure, or almost 0.

55 °C.
9. Measure the pump delivery pressure and PC
(Turning 2-stage relief ON switches to high-
pressure relief)
• Work equipment: Arm IN relief
a Judgment method:
7. Connect hose [2] and oil pressure gauge [3] of When the ratio of the pump discharge
hydraulic tester P3 to rear control pressure pressure to the PC valve output pressure
pressure pickup port (4). (servo piston inlet pressure) reaches the
following value, those pressures are normal.
a Use an oil pressure gauge of 60 MPa {600
kg/cm2}. Oil pressure to be Oil pressure ratio
measured
a The nipple and hose of digital hydraulic tester Rear pump delivery
pressure 1
P4 can also be used.
Rear PC valve output
Approx. 0.6 (approx. 3/5)
pressure
a If the PC valve or the servo piston is

defective, the PC valve output pressure
(servo piston inlet pressure) comes to the
same pressure as the pump delivery
pressure, or almost 0.
PC360LC-10 30-63
Hydraulic system
10.After finishing test remove the testing tools and

Measuring PC-EPC valve output pressure
the main pump.
• (5): Front PC mode selector pressure pickup
port (front of machine)
• (6): Rear PC mode selector pressure pickup
port (front of machine)

C.
5. Measure the hydraulic oil pressure with all the
control levers set to the NEUTRAL and the
engine running at low idle and at high idle.
• Swing lock switch: OFF
a When the front PC-EPC valve output
2. Install nipple P1 to each pressure pickup port. pressure changes as shown below, it is
normal.
a When installing nipple P1, be sure to install Engine Oil pressure
Control lever
O-ring P2.
1.74 MPa {17.7 kg/
3. Connect hose [2] and oil pressure gauge [3] of Low idle cm2}
hydraulic tester P3 to front PC mode selector NEUTRAL
0.22 MPa {2.2 kg/
pressure pickup port (5). High idle
cm2}
a Use an oil pressure gauge of 6.0 MPa {60 kg/
cm2}.

30-64 PC360LC-10
Hydraulic system
7. Connect hose [2] and oil pressure gauge [3] of

hydraulic tester P3 to rear PC mode selector
pressure pickup port (6).
cm2}.

Adjusting (PC300-C2A3-270-K-00-A)
a If either of the following problem occurs and the

PC valve seems to be defective, adjust PC
valves (7) and (8).
• As the work load increases, the engine
speed decreases remarkably.
• The engine speed is normal but the work
equipment speed is low.
a The width across flats of the PC valve lock nut is
13 mm and that (inside width) of the adjusting
screw is 4 mm. Do not turn any lock nuts and
adjustment screws other than the above,
because doing so affects the main pump
performance.
• (7): Front pump PC valve
• (8): Rear pump PC valve

C.
9. Measure the hydraulic oil pressure with all the
control levers set to the NEUTRAL and the
• Swing lock switch: OFF
a When the rear PC-EPC valve output
pressure changes as shown below, it is
normal.
Engine Control lever Oil pressure 1. Loosen lock nut (9).
1.74 MPa {17.7 kg/ a Before loosening lock nut (9), make a match
Low idle cm2}
NEUTRAL mark on the end face of adjustment screw
0.22 MPa {2.2 kg/ (10) to indicate the original position of the
High idle
cm2}
adjustment screw (so that you can return the
adjustment screw to the original position if
you turn it in the opposite direction).
2. Adjust the pressure by rotating adjustment
screw (10) to the clockwise or counterclockwise.
PC360LC-10 30-65
Hydraulic system
a Turn adjustment screw (10):

• to clockwise when the work equipment
speed is low (to increase pump
absorption torque).
• to counterclockwise when the engine
speed lowers (to decrease pump
absorption torque).
a Following indicates the range of adjustment
available from the adjusting screw.
Counterclockwise: Within 1 turn
Clockwise: Within 1/2 turn (Within 180 deg.)
3. Tighten lock nut (9).
3 Lock nut (9):
27 to 34 Nm {2.8 to 3.5 kgm}
4. After finishing adjustment, check again that the

PC valve output pressure (servo piston inlet
pressure) is normal according to the above
measuring procedure.
30-66 PC360LC-10
Hydraulic system
Testing and adjusting oil pressure in pump LS control circuit (PC300-C2A4-001-K-00-

A)
a Testing tools
Sym-
Part No. Part name
bol
Sensor adapter
796T-440-1101 (50 MPa {500 kg/cm2})
796-440-1150 • Wiring harness
796T-440-1160 • Nipple
1
799-401-2350 • Washer
799-401-2340 • Coupling
07002-61823 • O-ring
7861-93-1812 • Pressure sensor
2 799-101-5220 Nipple (M10 × 1.25 mm)
Q 3 07002-11023 O-ring
a To measure the LS pressure (actuator load
799-101-5002 Hydraulic tester pressure), measure the front and rear pump
790-261-1150 • Hose delivery pressures simultaneously and calculate
• Pressure gauge (60 the difference.
4 799-101-5110 MPa {600 kg/cm2})
799-101-5130 the main pump.
MPa {60 kg/cm2})
5 790-261-1204 Digital hydraulic tester • (1): Front pump LS pressure pickup port (rear
Differential pressure of machine)
6 799-401-2701 gauge • (2): Rrear pump LS pressure pickup port
(rear of machine)
a Before measuring the oil pressure in the LS

control circuit, check that the oil pressure in the
work equipment, swing, and travel circuits and
the oil pressure of the control circuit are normal.
a Measure the LS valve output pressure (servo
piston inlet pressure) under the following
conditions. 2. Install nipple Q2 to each pressure pickup port.
• Hydraulic oil temperature: 45 to 55 °C a When installing nipple Q2, be sure to install
Testing (PC300-C2A4-362-K-00-A)
O-ring Q3.
3. Connect sensor adapter assembly Q1 to front
Measuring LS differential pressure with the LS pressure pickup port (1).
machine monitor
a LS pressure (actuator load pressure) can be
checked on the "Monitoring/Pre-defined" or
"Monitoring" screen of the machine monitor by
using service oil pressure connector (11) (CN-
P49).
PC360LC-10 30-67
Hydraulic system
4. Connect service oil pressure connector (CN-

P49) (11) and sensor adapter assembly Q1.
7. While running the engine at high idle under the

following condition, measure the pump delivery
5. Start the engine and set the machine monitor to pressure and LS pressure (actuator load
"Monitoring/Pre-defined" or "Monitoring" screen. pressure) simultaneously.
a For the setting method, see "Special • Working mode: power mode (P)
functions of machine monitor". • Travel speed: Hi
• Work equipment, swing, and travel: Measure
• Monitoring code: 01100 "F Pump Pressure"
when all of these levers are in NEUTRAL
• Monitoring code: 01141 "Service Pressure and when the travel lever is moved halfway
Sensor" (to run the raised track shoe idle).
• "Monitoring/Pre-defined (10/14)" screen
k Run the raised track idle, paying enough
attention to the surroundings for safety.
a Calculation of LS differential pressure:
LS differential pressure See standard value table
9. Connect sensor adapter assembly Q1 to rear LS
• "Monitoring" screen
10.Connect service oil pressure connector (P49)

(11) and sensor adapter assembly Q1.

55°C and raise the track of the measured side.
• When measuring the front circuit: left track
shoe
k Provide a enough work space to run the

track idle off the ground.
30-68 PC360LC-10
Hydraulic system
11.Start the engine and set the machine monitor to

13.While running the engine at high idle under the
a For the setting method, see "Special pressure and LS pressure (actuator load
functions of machine monitor". pressure) simultaneously.
• Monitoring code: 01101 "R Pump Pressure" • Working mode: power mode (P)
• Monitoring code: 01141 "Service Pressure • Travel speed: Hi
Sensor" • Work equipment, swing, and travel: Measure
• "Monitoring/Pre-defined (11/14)" screen when all of these levers are in NEUTRAL
and when the travel lever is moved halfway
(to run the raised track shoe idle).

a Calculation of LS differential pressure:
LS differential pressure = pump delivery
pressure – LS pressure
LS differential pressure See standard value table
• "Monitoring" screen Measuring LS valve output pressure (servo

piston inlet pressure)
a To measure the LS valve output pressure (servo
piston inlet pressure), measure the front and
rear pump delivery pressures simultaneously
and compare them.
the main pump.
• (3): Front control pressure pickup port
12.Increase the hydraulic oil temperature to 45 to • (4): Rear control pressure pickup port
• When measuring the rear circuit: right track
shoe

PC360LC-10 30-69
Hydraulic system
2. Install nipple Q2 to each pressure pickup port. 5. Measure the pump delivery pressure and LS
a When installing nipple Q2, be sure to install
O-ring Q3.
hydraulic tester Q4 to front control pressure
pickup port (3). • Working mode: power mode (P)
a Use an oil pressure gauge of 60 MPa {600 when all of these levers are in NEUTRAL
kg/cm2}. and when the travel lever is moved halfway
a The nipple and hose for digital hydraulic (to run the raised track shoe idle).
tester Q5 can also be used.
a Measurement conditions and judgment
method:
When the ratio between the pump delivery
pressure and LS valve output pressure
(servo piston input pressure) reaches the
following value, LS valve is normal.

55°C and raise the track of the side to be tested
off the ground with work equipment.
shoe

30-70 PC360LC-10
Hydraulic system
Operation of lever
All control Travel lever at
levers and half stroke (truck
pedals in running idle off
NEUTRAL ground)
Front pump Actual measured
Oil pressure to
delivery value is regarded

be measured
pressure Almost as 1.
same
Front LS pressure Approx. 0.6 (3/5)
valve output
of above pressure
pressure
55°C and raise the track of the side to be tested
off the ground with work equipment.
shoe


hydraulic tester Q4 to rear control pressure
pickup port (4).
kg/cm2}.
a The nipple and hose for digital hydraulic 9. Measure the pump delivery pressure and LS
tester Q5 can also be used. valve output pressure (servo piston inlet

a Measurement conditions and judgment
method:
When the ratio between the pump delivery
pressure and LS valve output pressure
(servo piston input pressure) reaches the
following value, LS valve is normal.
PC360LC-10 30-71
Hydraulic system
Operation of lever
All control Travel lever at
levers and half stroke (truck
pedals in running idle off
NEUTRAL ground)
Rear pump Actual measured
Oil pressure to
delivery value is regarded

be measured
pressure Almost as 1.
same
Rear LS pressure Approx. 0.6 (3/5)
valve output
of above pressure
pressure
2. Install nipple Q2 to each pressure pickup port.
a When installing nipple Q2, be sure to install
O-ring Q3.
3. Connect hose [2] and oil pressure gauge [3] or
differential pressure gauge Q6 of hydraulic
tester Q4 to front pump LS pressure pickup port
(1).
a When using the oil pressure gauge:
kg/cm2}.
a The max. differential pressure is no more
10.After finishing test remove the testing tools and than approximately 3.9 MPa {40 kg/cm2}. So
restore the machine. the same gauge may be used throughout the
measurement.
Measuring LS differential pressure with oil
pressure gauge a The nipple and hose for digital hydraulic
a To measure the LS pressure (actuator load
pressure), measure the front and rear pump
delivery pressures simultaneously and calculate
the difference.
the main pump.
• (1): Front pump LS pressure pickup port (rear
of machine)
• (2): Rrear pump LS pressure pickup port
(rear of machine)
30-72 PC360LC-10
Hydraulic system
a When using differential pressure gauge Q6: a Calculating LS differential pressure (when
Connect the pump delivery pressure hose to the pressure gauge is used):
the high pressure side (back side) and LS differential pressure = pump delivery
connect the LS pressure hose to the low pressure – LS pressure
pressure side (lower side). LS differential pressure See standard value table
a The differential pressure gauge needs 12 V 6. After finishing test, remove the testing tools and
DC power, so connect it to a battery. restore the machine.
7. Connect hose [2] and oil pressure gauge [3] or
differential pressure gauge Q6 of hydraulic
tester Q4 to rear pump LS pressure pickup port
(2).
a When using the oil pressure gauge:
kg/cm2}.

shoe


pressure and LS pressure (actuator load
pressure) simultaneously. a When using differential pressure gauge Q6:
• Working mode: power mode (P) Connect the pump delivery pressure hose to
• Travel speed: Hi the high pressure side (back side) and
• Work equipment, swing, and travel: Measure connect the LS pressure hose to the low
when all of these levers are in NEUTRAL pressure side (lower side).
(to run the raised track shoe idle). a The differential pressure gauge needs 12 V
DC power, so connect it to a battery.
PC360LC-10 30-73
Hydraulic system
• (7): LS set selector pressure pickup port

2. Install nipple Q2 to the pressure pickup port.
shoe a When installing nipple Q2, be sure to install
O-ring Q3.
k Provide a enough work space to run the 3. Connect hose [2] and oil pressure gauge [3] of
track idle off the ground. hydraulic tester Q4 to rear LS set selector
cm2}.

pressure and LS pressure (actuator load
pressure) simultaneously.
• Travel speed: Hi

a Calculating LS differential pressure (when
the pressure gauge is used):
LS differential pressure = pump delivery
pressure – LS pressure
LS differential pressure See standard value table 4. Start the engine and keep it running until the
10.After finishing test remove the testing tools and hydraulic oil temperature increases to 45 to 55°
restore the machine. C.
5. Measure the oil pressure when the engine is
Measuring LS-EPC valve output pressure running at high idle and the travel speed switch
1. Remove pressure pickup port plug (7) of the and travel control lever are operated.
main pump.
30-74 PC360LC-10
Hydraulic system
a When LS-EPC valve output pressure a Quantity of adjustment per turn of adjustment
changes to the following values, the pressure screw (10) (LS differential pressure):
is normal. Approximately 1.3 MPa {approximately 13.3
Travel speed Travel lever Oil pressure kg/cm2}
Fine control Approx. 1.45 MPa 3. While fixing adjustment screw (10), tighten lock
Lo (Note) {approx. 14.8 kg/cm2} nut (11).
Fine control
Hi 0 MPa {0 kg/cm2} 3 Lock nut (11):
(Note)
49 to 64 Nm {5 to 7 kgm}
Note: Operate the travel lever slightly to a
degree that the PPC oil pressure switch turns
ON (before the machine starts to move).
4. After finishing adjustment, check that the LS

differential pressure is normal in the above
6. After finishing test, remove the testing tools and measuring procedure.
Adjusting (PC300-C2A4-270-K-00-A)
a If the LS differential pressure is improper, adjust

LS valves (8) and (9) according to the following
procedure.
• (8): Front pump LS valve
• (9): Rear pump LS valve
1. While fixing adjustment screw (10), loosen lock

nut (11).
pressure.
a If the adjustment screw is:
• turned clockwise, the differential pressure
is increased.
• turned counterclockwise, the differential
pressure is decreased.
PC360LC-10 30-75
Hydraulic system
Testing outlet pressure of solenoid valve (PC300-PQPT-001-K-00-A)
a Testing tools
Sym-
Part No. Part name
bol
799-101-5160 • Nipple (R1/8)
1 790-261-1150 • Hose
799-101-5130 MPa {60 kg/cm2})
R
799-401-3100 Adapter (size: 02)
3
02896-11008 O-ring
799-401-3200 Adapter (size: 03)
4
02896-11009 O-ring

a Before measuring the solenoid valve outlet

pressure, check that the control circuit oil
pressure is proper.
a Measure the solenoid valve outlet pressure
under the following condition.
Testing (PC300-PQPT-362-K-00-A) 2. Increase the hydraulic oil temperature to 45 to
Measuring with machine monitor 55 °C.
3. While running the engine at high idle, operate
a Solenoid valve outlet pressure can be checked each control lever and each switch to turn each
on the "Monitoring" screen of the machine solenoid valve ON and OFF, and check the
monitor. "Monitoring" screen.
1. Start the engine and set the machine monitor to
a For the conditions for turning ON or OFF, see
"Monitoring" screen.
the operation table of each solenoid valve.
a For the setting method, see "Special
a When the state of the solenoid valve shown
functions of machine monitor".
on the "Monitoring" screen is "ON", it is
• Monitoring code: 02300 "Solenoid 1" normal.
• Monitoring code: 02301 "Solenoid 2"
• "Monitoring" screen Measuring with oil pressure gauge
1. Disconnect outlet hoses (1) to (8) of the solenoid
valves to be measured.
No. Solenoid valve to be measured
1 PPC lock solenoid valve
2 Swing motor 2-stage relief solenoid valve
3 Travel junction solenoid valve
4 Travel speed solenoid valve
5 Swing holding brake solenoid valve
6 Machine push-up solenoid valve
Attachment selector solenoid valve (for
7 machines equipped with attachment)
8 2-stage relief solenoid valve
30-76 PC360LC-10
Hydraulic system
a When testing at hose (1), remove the

undercover (rear side) of the operator's cab.

C.
a When testing at hoses (2) to (8), remove the 5. While running the engine at high idle, operate
top cover of the control valve. each control lever and each switch to turn each
solenoid valve ON and OFF, and measure the oil
pressure.
a For the conditions for turning ON or OFF, see
the operation table of each solenoid valve.
Solenoid valve outlet See standard value
pressure table
2. Install adapter R3 or R4 and reconnect the

hoses.
3. Connect nipple [1], hose [2], and oil pressure
gauge [3] in hydraulic tester R1.
a Use an oil pressure gauge of 6 MPa {60 kg/
cm2}.
tester R2 can also be used.
a The figure shows the testing tools connected
to the outlet hose (3) of travel junction
solenoid valve.
PC360LC-10 30-77
Hydraulic system
Operating condition (PC300-PQPT-04C-K-00-A)
(1) Operation table of 2-stage relief solenoid valve

Overheat 1st setting is ON.
Overheat 2nd setting is ON. OFF
When all the signals for work equipment, swing and travel are OFF.
Swing lock switch is ON.
Travel signal is ON.
When L mode is selected. ON
When the boom LOWER signal is ON.
Signals other than the "swing only"
When one-touch power max. are ON.
In P or E mode
switch is ON. "Swing only " is ON.
OFF
Other than the above conditions
(2) Operation table of attachment selector solenoid valve (for machines equipped with attachment)
Working mode: other than B mode OFF
Working mode: when B mode is set ON
(3) Operation table of machine push up solenoid valve
OFF ON
Machine push-up switch
ON OFF
(4) Operation table of swing holding brake solenoid valve
Signals of work equipment and swing (Work All are OFF. OFF
equipment includes attachment.) Any one is ON. ON
(5) Operation table of travel speed increase solenoid valve
Overheat 2nd setting is ON.
Fuel control dial is at 1,200 rpm or below.
Travel speed switch is at Lo.
OFF
Travel signal is OFF.
When F or R pump pressure is 32.3
Travel speed switch is at Mi or MPa {330 kg/cm2} or above.
Hi. Travel signal is ON.
When F or R pump pressure is 18.6
MPa {190 kg/cm2} or below. ON
Other than the above conditions
(6) Operation table of travel junction solenoid valve
Travel steering signal is ON.
When " travel only" When F or R pump pressure is 24.5 ON
Travel steering signal is OFF. signal is ON. MPa {250 kg/cm2} or above.
Other than the above conditions OFF
30-78 PC360LC-10
Hydraulic system
(7) Operation table of swing 2-stage relief solenoid valve

When boom When R pump
When boom RAISE PPC pressure is rising
RAISE pressure is 2.2 and 18.6 MPa
signal is ON. MPa {22 kg/cm2} {190 kg/cm2} or
When the swing signal is
or below. When arm above.
ON but except when the
signal is When R pump ON
swing back operation is
OFF. pressure is
turned on.
When pump flow is divided. dropping and
25.5 MPa {260
kg/cm2} or
above.
Other than the above conditions OFF
(8) Operation table of PPC lock solenoid valve
At LOCK position OFF
PPC lock lever
At FREE position ON
PC360LC-10 30-79
Hydraulic system
Testing PPC valve output pressure (PC300-PW11-001-K-00-A)
a Testing tools • Monitoring code: 07102 "Travel Fwd L.H.

Sym- PPC Pressure"
Part No. Part name • Monitoring code: 07103 "Travel Fwd R.H.
bol
799-101-5002 Hydraulic tester PPC Pressure"
799-101-5160 • Nipple (R1/8) • Monitoring code: 07104 "Travel Rev L.H.
1 PPC Pressure"
790-261-1150 • Hose
• Monitoring code: 07105 "Travel Rev R.H.
799-101-5130 MPa {60 kg/cm2}) PPC Pressure"
S • "Monitoring/Pre-defined (12/14)" screen
799-401-3100 Adapter (size: 02)
3
02896-11008 O-ring
799-401-3200 Adapter (size: 03)
4
02896-11009 O-ring

a Before measuring the PPC valve output

pressure, ensure that the control circuit oil 2. Increase the hydraulic oil temperature to 45 to
pressure is proper. 55 °C.
3. Measure the pressure when the engine is
a Measure the PPC valve output pressure under running at high idle and the control lever of the
the following conditions. circuit to be measured is kept at NEUTRAL
• Hydraulic oil temperature: 45 to 55 °C position and at the full stroke.
Testing (PC300-PW11-362-K-00-A) a When the output pressure of PPC valve is as
Measuring with machine monitor follows, it is normal.
Operation of lever Output pressure
a PPC valve output pressure can be checked on
NEUTRAL 0 MPa {0 kg/cm2}
the "Monitoring/Pre-defined" or "Monitoring"
screen of the machine monitor. Nearly equal to control
At stroke end circuit pressure (see
1. Start the engine and set the machine monitor to standard value table)
a For the setting method, see "Special Measuring with oil pressure gauge
functions of machine monitor". 1. Disconnect PPC circuit oil pressure hoses (1) to
(10) to be measured.
• Monitoring code: 07200 "Arm Curl (IN) PPC
Pressure" No. Circuit to be measured
• Monitoring code: 07600 "Arm Dump (OUT) 1 Bucket Curl
PPC Pressure" 2 Boom Lower
• Monitoring code: 07300 "Bucket Curl PPC 3 Right swing
Pressure" 4 Arm Curl (IN)
• Monitoring code: 07301 "Bucket Dump PPC 5 Bucket Dump
Pressure" 6 Boom Raise
• Monitoring code: 07400 "Boom Raise PPC Left swing
7
Pressure"
8 Arm Dump (OUT)
• Monitoring code: 07500 "Boom Lower PPC
Pressure" 9 Left travel reverse
• Monitoring code: 09001 "Swing Left PPC 10 Right travel reverse
Pressure" 11 Right travel forward
• Monitoring code: 09002 "Swing Right PPC 12 Left travel forward
Pressure"
30-80 PC360LC-10
Hydraulic system
a When checking hoses (1) to (8), disconnect

them at the junction block. When checking
hoses (9) to (12), disconnect them at the oil
pressure sensor connections under the
operator's cab.

C.
5. Measure the pressure when the engine is
running at high idle and the control lever of the
circuit to be measured is kept at NEUTRAL
position and at the full stroke.
a When the output pressure of PPC valve is as
follows, it is normal.
Operation of lever Output pressure
Nearly equal to control
At stroke end circuit pressure (see
standard value table)
2. Install adapter S3 or S4 and connect the hoses

again which have been disconnected.
3. Connect nipple [1], hose [2], and oil pressure
gauge [3] in hydraulic tester S1.
a Use an oil pressure gauge of 6 MPa {60 kg/
cm2}.
tester S2 can also be used.
a The figure shows the testing tools connected
to the measuring point of the bucket curl (1)
circuit.
PC360LC-10 30-81
Hydraulic system
Adjusting play of work equipment and swing PPC valves (ALL-PL28-001-K-00-A)
a If the right and left work equipment levers have

large play, adjust them according to the following
procedure.
a The play of the lever measured at a position of
200 mm from the pivot must be 0.5 to 3 mm.
Adjusting (PC400-PL28-270-K-00-A)
1. Remove boot (1).

2. Loosen locknut (2) and tighten disc (3) until it
touches the heads of 4 pistons (4).
a Do not move the piston at this time.
3. Fix the position of disc (3) and tighten locknut (2)
3 Locknut:
69 to 88 Nm {7 to 9 kgm}
4. Install boot (1).
30-82 PC360LC-10
Hydraulic system
Testing pump swash plate sensor (PC200_10-C3WG-360-K-00-A)
a Before testing pump swash plate sensor, check a Testing condition and judgment: If the voltages
that oil pressure in work equipment, swing, and are as shown in the table, pump swash plate
travel circuits, control circuit source pressure, sensor is correct.
and no-load travel speed are correct. Pump swash plate
Lever control sensor voltage
a Test pump swash plate sensor under the
following conditions. All control levers and
pedals are at neutral. 1.56 ± 0.63 V
• Hydraulic oil temperature: 45 to 55°C
Travel lever is at stroke
• Working mode: P mode end.
3.63 ± 0.63 V
Testing output voltage of pump swash plate (run track idle off
sensor ground)
a Output voltage of pump swash plate sensor can
be checked by using monitoring function of
machine monitor.
(For the operating method, see "Special
functions of machine monitor".)
• Monitoring code:
01138 "F pump sw plate sensor volt"
01140 "R pump sw plate sensor volt"
Testing (PC300-C3WG-36J-K-00-A)
1. Start the engine and raise the track on the side

to be tested, by using the work equipment, and
prepare for running the track idle.
• When testing front pump: left track
• When testing rear pump: right track
k Provide an enough work space to run the

2. Set the working mode to the Power Mode (P)

and set the travel speed to the High.
3. Set the swing lock switch to ON position.
4. While running the engine at high idle, set all the
levers and pedals for work equipment, swing,
and travel to the neutral, and then set the travel
lever to stroke end in order to run a track idle,
and measure the voltage during each operation.
k While taking care of safety around the
machine, run the raised track idle.
PC360LC-10 30-83
Hydraulic system
Isolating the parts causing hydraulic drift in work equipment (ALL-L410-001-K-00-A)
a If the work equipment (cylinder) drifts

hydraulically, perform check to see if the
problem is in the cylinder seal or control valve
Testing (PC-L410-360-K-00-A)
1. Checking boom cylinder and bucket cylinder

1) Set the work equipment in the same posture
as when measuring hydraulic drift, and stop
the engine.
a Put a weight equivalent to the rated load
or fill the bucket with the earth and sand.
2) Operate the arm control lever to the arm IN
position.
• If the lowering speed is increased at this
time, the cylinder seal is defective.
• If the lowering speed does not change at
this time, the control valve is defective.
a Operate the control lever with the engine
starting switch in ON position.
a If there is no more pressure in the
accumulator, run the engine for
approximately 10 seconds to charge the
accumulator.
2) When testing the boom cylinder, set the [Reference] In case of the hydraulic drift is
boom control lever to RAISE position. caused by defective cylinder packing, the
When testing the bucket cylinder, set the reason why the drift speed becomes faster by
bucket control lever to CURL position. above mentioned operation is as follows:
• If the lowering speed is increased at this 1) If the work equipment is set to the above
time, the cylinder seal is defective. posture (where the work equipment holding
• If the lowering speed does not change at pressure is applied to the bottom side), the
this time, the control valve is defective. oil leaks from the bottom side to the head
a Operate the control lever with the engine side. The volume on the head side is less
starting switch in ON position. than that on the bottom side by the volume of
the rod, so the pressure in the head side is
a If there is no more pressure in the increased by the oil flowing in from the
accumulator, run the engine for bottom side.
approximately 10 seconds to charge the 2) As the inner pressure in the head side is
accumulator. increased, it is balanced with the pressure in
2. Checking arm cylinder the bottom side at a certain level (which
1) Move the arm cylinder to approximately 100 depends on the leak quantity), and the
mm before the IN stroke end and stop the lowering speed is reduced.
engine. 3) If the circuit on the head side is opened to
the drain circuit by the above operation of the
lever (the bottom side is closed by the check
valve at this time), the oil in the head side
flows in the drain circuit. As a result, the
pressure is in balanced and the lowering
speed is increased.
3. Testing PPC valve
Measure the hydraulic drift of the work
equipment when the work equipment lock lever
is in LOCK and FREE positions with the
accumulator charged fully.
30-84 PC360LC-10
Hydraulic system
a Operate the control lever with the engine

starting switch in ON position.
a If there is no more pressure in the
accumulator, run the engine for
approximately 10 seconds to charge the
accumulator.
a If there is any difference in the hydraulic drift
between LOCK and FREE positions, the
PPC valve is defective (some internal
defect).
PC360LC-10 30-85
Hydraulic system
Testing oil leakage (ALL-C000-001-P-03-A)
a Component to be checked k Release the remaining pressure from

Sym- the piping on the arm cylinder head
Part No Part Name side. For details, see “Releasing
bol
Available on remaining pressure from hydraulic
T Measuring cylinder
the market circuit” (Operate the lever in the arm
IN direction only, however).
a Measure the oil leakage under the following
condition. 2) Disconnect hose (2) on the cylinder head
side and block the hose end by a flange.
Testing (PC300-C000-364-K-00-A) k Take care not to disconnect the hose
1. Measuring oil leakage from boom cylinder on the cylinder bottom side.
1) Extend the boom cylinder to the boom a Use the following part to block on the
RAISE stroke end and stop the engine. hose end.
07379-01044 (Flange #10)
k Release the remaining pressure from
the piping on the boom cylinder head
side. For details, see “Releasing
remaining pressure from hydraulic
circuit”. (Operate the lever in the boom
RAISE direction only, however).
2) Disconnect hose (1) on the cylinder head
k Take care not to disconnect the hose

on the cylinder bottom side.
a Use the following part to block on the
hose end. 3) Run the engine at high idle and relieve the
07379-01044 (Flange #10) arm circuit by moving the arm IN.
k Take care not to operate "arm OUT".

4) Start measuring the oil leakage 30 seconds
after relieving is started, and measure the
leak for 1 minute.
5) After finishing test, restore the machine.
3. Measuring oil leakage from bucket cylinder
1) Move the bucket cylinder to the bucket
CURL stroke end and stop the engine.
k Referring to Release of remaining

pressure from hydraulic circuit,
3) Run the engine at high idle and relieve the release the remaining pressure from
boom circuit by raising the boom. the piping on the bucket cylinder head
side (Operate the lever only in the
CURL direction, however).
k Take care not to "lower the boom".
2) Disconnect hose (3) on the cylinder head
4) Start measuring the oil leakage 30 seconds
after relieving is started, and measure the
leak for 1 minute.
k Take care not to disconnect the hose
2. Measuring oil leakage from arm cylinder on the cylinder bottom side.
1) Move the arm cylinder to the arm IN stroke a Use the following part to block on the
end and stop the engine. hose end.
07379-01044 (Flange #10)
30-86 PC360LC-10
Hydraulic system
k Insert pin [1] between the sprocket

and the track frame to securely lock
the track.
3) Run the engine at high idle and relieve the

bucket circuit by curling the bucket.
k Takecare not to operate "bucket 3) Disconnect drain hose (5) of the travel motor
DUMP". and block the hose end by a plug.
4) Start measuring the oil leakage 30 seconds a Use the following part to block on the
after relieving is started, and measure the hose end.
leak for 1 minute.
07376-70522 (Plug#05)
4. Measuring oil leakage from swing motor
1) Disconnect drain hose (4) and block the
hose end with plugs.
a Use the following part to block on the
hose end.
07376-70522 (Plug#05)
4) Start the engine and run it at high idle, relieve

the travel circuit, and measure the oil
leakage.
k Before operating the travel lever,

check the pin position and locked
direction of the travel again.
2) Set the swing lock switch to ON position.
3) Start the engine and run it at high idle and k Wrong operation of the lever can
perform swing relief. cause the personal injury. Make the
signals and checks securely.
a Start measuring the oil leakage 30
seconds after relieving is started, and a Start measuring the oil leakage 30
measure the leak t for 1 minute. seconds after relieving is started, and
measure the leak t for 1 minute.
a After Measuring one time, swing 180 deg.,
and then measure again. a Measure several times while moving the
4) After finishing test, restore the machine. motor a little (changing the position of the
5. Measuring oil leakage from travel motor valve plate and cylinder, and that of the
cylinder and piston) each time.
1) Remove the travel motor cover.
2) Start the engine, lock the travel mechanism,
and stop the engine.
PC360LC-10 30-87
Hydraulic system
Bleeding air from hydraulic circuit (ALL-C000-001-P-04-A)
q: Execution of work
o: Go to next procedure
Air bleeding procedure and item
1 2 3 4 5 6
Bleeding air Checking oil
from Starting the Bleeding air Bleeding air Bleeding air
level and
hydraulic engine from cylinder from swing from travel
operating
pump motor motor
machine
• Replacement of
hydraulic oil q q
q q q q
• Cleaning (See note) (See note)
strainer
• Replacing
return oil filter q o o o q
element
• Replacing or
repairing
hydraulic pump q q q o o q
• Removal of
suction piping
• Replacing or
repairing
control valve
q q o o q
• Removal of
Detail of work, remarks
control valve
piping
• Replacement
or repair of
cylinder q q o o q
• Removal of
cylinder piping
• Replacing or
repairing swing
motor
q o q o q
• Removal of
swing motor
piping
• Replacing or
repairing travel
motor
q o o q q
• Removal of
travel motor
piping
• Replacing or
repairing swivel
joint q o o o q
• Installing swivel
joint piping
Note: Bleed air from the swing motor and travel motor only when the oil in the motor cases is drained.
30-88 PC360LC-10
Hydraulic system
Bleeding air (PC300-C000-231-P-01-A)
1. Bleeding air from main pump 5) Bleed air from the arm cylinder and bucket
cylinder according to steps 2) to 4).
a Keep the oil filler cap of the hydraulic tank
4. Bleeding air from swing motor
loosened while the air bleeding from the
main pump is being performed. 1) Start the engine and run it at low idle.
2) Swing to the right and left slowly to bleed air.
1) Loosen air bleeder (1) and check that the oil
5. Bleeding air from travel motor
oozes out of the air bleeder.
2) When the air-free oil starts to flow out, tighten 1) Start the engine and run it at low idle.
air bleeder (1). 2) Loosen air bleeder (2) and check that the oil
oozes out of the air bleeder.
3 Air bleeder: 3) When the air-free oil starts to flow out, tighten
7.8 to 9.8 Nm {0.8 to 1.0 kgm} air bleeder (2).
3 Air bleeder:
27.5 to 35.3 Nm {2.8 to 3.6 kgm}
2. Starting engine
When running the engine after performing step 1,
let it low-idle for 10 minutes.
6. Bleeding air from swivel joint
a When the automatic warm-up operation is
1) Start the engine and run it at low idle.
performed because of low engine coolant
2) Lift the track on one side at a time, then
temperature, stop the engine once and
bleed air by slowly running it idle (in L.H.
cancel it by using the fuel adjustment dial.
travel, R.H. travel, forward and reverse).
(You can cancel the automatic warm-up
7. Checking oil level and starting work
operation by holding the fuel adjustment dial
in MAX position for 3 seconds or longer after 1) Run the engine, retract the arm cylinder and
turning the starting switch to ON position.) bucket cylinder to the stroke ends, lower the
3. Bleeding air from cylinder work equipment to the ground, and stop the
engine.
a When the cylinder is replaced, the air
bleeding should be done before connecting
the work equipment. In particular, the boom
cylinder rod does not move to the LOWER
stroke end after it is connected to the work
equipment.
1) Run the engine at low idle for approximately
5 minutes.
2) While running the engine at low idle, raise
and lower the boom 4 to 5 times.
a Stop the piston rod approximately 100
mm before each stroke end. Do not
cause the relief.
3) While running the engine at high idle, 2) Check the oil level by using sight gauge (3)
perform step 2). on the rear side of the hydraulic tank.
4) While running the engine at low idle speed, a The oil level is acceptable if it is between
move the piston rod to the stroke end and H and L lines.
relieve the oil.
PC360LC-10 30-89
Hydraulic system
a If the oil level is below line L, it is

insufficient. Add oil.
30-90 PC360LC-10
Cab and its attachments
Checking cab tipping stopper (ALL-K138-001-K-00-A)
a Check the cab tipping stopper according to the following procedure.

Testing (PC-K138-280-K-00-A)
1. Check the tightening torque of the mounting bolt

(2) of the lock plate (1).
3 Bolt (2):
98 to 123 Nm {10 to 12.5kgm}
[Reference]
• Note that the tightening torque for mounting bolt
(4) of cab tipping stopper (3) is different from that
of a common bolt 30 mm in diameter.
3 Bolt (4):
245 to 309 Nm {25 to 31.5kgm}
PC360LC-10 30-91
Adjusting mirrors (PC300-K810-001-K-00-A)
1. Mirror installing positions 3 Mounting bolt (4):

6.0 to 7.0 Nm {0.61 to 0.71 kgm}
2. Adjusting mirror (a)

Adjust mirror (a) so that the operator can see a
person in the rear left end of the machine.
• Adjust the mirror so that the side of the
machine is reflected in it as shown below.
a Tighten bolts for the brackets alternately

while keeping the left and right clearances
(L) and (R) equal.
a Install the mirror and stay to dimensions as a Excessive tightening of the mirror and the
shown below. stay mounting bolts may damage the bracket.
• Stay (1) Tighten them to the specified torque.
(D): 65 mm, (E): 83 deg.
15.0 to 19.6 Nm {1.52 to 2 kgm}
• Mirror (3)
(F): 169 mm, (G): 88 deg.
3. Adjusting mirror (b)

Adjust mirror (b) so that the operator can see a
person at the right rear end of the machine.
• Adjust the mirror so that the side of the
machine is reflected in it as shown below.
30-92 PC360LC-10
a Excessive tightening of the mirror and the

stay mounting bolt can damage the bracket.
Tighten them to the specified torque.
a Install the mirror and stay to dimensions as

shown below.
• Stay (5)
4. Adjusting mirror (c)
(H): 420 mm, (J): 60 deg.
Adjust the mirror (c) so that the operator can see
3 Mounting bolt (6): persons on the ground at around the machine
15.0 to 19.6 Nm {1.52 to 2 kgm} (W).
• Mirror (7) (W): 1 m
(K): 143 mm, (M): 17 deg., (Q): 3 deg.
6.0 to 7.0 Nm {0.61 to 0.71 kgm}
a Install the mirror to dimension as shown

below.
• Mirror (9)
(N): 9 mm, (P): 53 deg.
6.0 to 7.0 Nm {0.61 to 0.71 kgm}
a Tighten bolts for the brackets alternately

while keeping the left and right clearances
(L) and (R) equal.
PC360LC-10 30-93
30-94 PC360LC-10
Electrical system
Special functions of machine monitor (PC220-Q170-042-K-01-A)
PC360LC-10 30-95
Electrical system
Upper part of machine monitor (display portion)

(a): Multi-information display
a When the engine is started, the battery voltage
may drop suddenly, depending on the ambient
temperature and the condition of the battery.
In this case, the screen display of the machine
monitor may go off for a moment. This
phenomenon is not a failure, however.
Upper part of machine monitor (switch portion)

[F1]: F1 Function switch
a The function of each function switch is indicated
by the icon which is displayed just above the
function switch on the screen of the multi-
information display panel (a).
a If the icon for a function switch is not displayed,
that function switch is not working.
Lower part of machine monitor (switch portion)

[1]: Numeral 1 input switch/Auto-deceleration switch
[2]: Numeral 2 input switch/Working mode selector
switch
[3]: Numeral 3 input switch/Travel speed selector
switch
[4]: Numeral 4 input switch/Alarm buzzer stop
switch
[5]: Numeral 5 input switch/Wiper switch
[6]: Numeral 6 input switch/Window washer switch
[7]: Numeral 7 input switch/Air conditioner switch
Switch having no numerals : Air conditioner switch
a Each switch has the function indicated by the
icon on it and the function of inputting a numeral.
a The machine monitor automatically judges which
function of each switch is currently enabled
according to the screen display of the multi-
information display panel (a).
30-96 PC360LC-10
Electrical system
Ordinary functions and special functions of machine monitor (PC300-Q170-042-K-00-A)
The machine monitor has the ordinary functions and special functions and displays information of various
types on the multi-information display panel.
Some information are displayed automatically according to the configuration of the machine monitor and the
others are displayed according to the operation of the switches.
1. Ordinary functions: Operator mode
The information items in this mode are displayed ordinarily. The operator can display and set them by
operating the switches (Display and setting of some items need special operations of the switches).
2. Special function: Service mode
The information items in this mode are not displayed ordinarily. Each technician can display them by
operating the switches specially.
This mode is used for special setting, testing, adjusting, or troubleshooting.
Operator mode (outline) Service mode

A Display of KOMATSU logo(PAGE 30-99) Monitoring / Pre-defined(PAGE 30-115)
A Password input(PAGE 30-99) Monitoring(PAGE 30-119)
Display of check of breaker mode(PAGE 30- Abnormality record (mechanical systems)(PAGE
A 100) 30-126)
Display of “check before starting”(PAGE 30- Abnormality record (electrical systems)(PAGE 30-
A 100) 127)
Display of warning after check before starting
A Maintenance Record(PAGE 30-128)
(PAGE 30-100)
Display of maintenance due time over(PAGE
A Maintenance Mode Setting(PAGE 30-129)
30-101)
Display of check of working mode and travel
A Phone number entry(PAGE 30-132)
speed(PAGE 30-101)
A Display of standard screen(PAGE 30-101) Default (Key-on Mode)(PAGE 30-132)
A Display of end screen(PAGE 30-101) Default value setting (Unit)(PAGE 30-133)
Display of operation screen for engine
A Default (With/Without Attachment)(PAGE 30-134)
shutdown secondary switch(PAGE 30-102)
B Selection of auto-deceleration(PAGE 30-102) Default (Camera)(PAGE 30-135)
(Special operation)
B Selection of working mode(PAGE 30-102) Testing (Cylinder Cut-out operation)(PAGE 30-136)

B Selection of travel speed(PAGE 30-103) Testing (Regeneration for Service)(PAGE 30-137)
B Operation to stop alarm buzzer(PAGE 30-103) Testing (KDPF Memory Reset)(PAGE 30-139)
Adjustment (Pump Absorption Torque (F))(PAGE
B Operation of windshield wiper(PAGE 30-103) 30-140)
Adjustment (Pump Absorption Torque (R))(PAGE
B Operation of window washer(PAGE 30-104) 30-140)
Operation of air conditioner/heater(PAGE 30- o Adjustment (Low Speed)(PAGE 30-141)
B 104)
Operation to display camera mode(PAGE 30- Adjustment (Attachment Flow Adjustment)(PAGE
B 104) 30-142)
Operation to display clock and service meter Adjustment (Cal F pump swash plate sensor)
B (PAGE 30-104) (PAGE 30-144)
Check of maintenance information(PAGE 30- Adjustment (Cal R pump swash plate sensor)
B 105) (PAGE 30-149)
Setting and display of user mode (including Adjustment (Pump calibration: Matching speed
B KOMTRAX messages for user)(PAGE 30-105) check)(PAGE 30-150)
Adjustment (Pump calibration: Matching speed
C Display of ECO guidance(PAGE 30-105) calibration)(PAGE 30-156)
C Display of caution monitor(PAGE 30-107) No Injection(PAGE 30-156)
KOMTRAX Settings (Terminal Status)(PAGE 30-
C Display of KDPF regeneration(PAGE 30-107) 157)
Display of action level and failure code(PAGE KOMTRAX Settings (GPS and Communication
C 30-110) Status)(PAGE 30-158)
KOMTRAX Settings screen (Modem Status)(PAGE
O (Special operation) 30-159)
PC360LC-10 30-97
Electrical system
Function of checking display of LCD (Liquid

D Crystal Display)(PAGE 30-111) Service Message(PAGE 30-159)
Function of checking service meter(PAGE 30-
D 111)
Function of Usage Limitation Setting/ Change
D Password(PAGE 30-111)
a Group of screens or functions in operator mode

A: Display or function from turning ON of starting switch to switching to the standard screen is over, and
display after starting switch is turned OFF
B: Display or function when the machine monitor switches are operated
C: Display or function when certain conditions are met
D: Display or function when operation of special switches is required
30-98 PC360LC-10
Electrical system
Operator mode (Outline) (PC300-Q193-042-K-00-A) a Display sequence in operator mode

a Only outline of the operator mode is described in The contents of display from the time when
this section. starting switch is turned ON to time when screen
changes to standard screen depends on the
For details of contents and operations of each
setting and condition of the machine.
function and display, see "Structure and
function", or the "Operation and Maintenance A: When the engine start lock is set effective
Manual". B: When the engine start lock is set ineffective
a The following are the screens or functions of the C: When working mode at start is set to breaker
operator mode explained in this section mode (B)
(including some items which need special D: When there is abnormal item in check-before-
operations). starting items
E: When an overdue maintenance item is
Display pattern discovered
A B C D E Display of KOMATSU logo (PC220-Q180-044-K-01-A)
Display of KOMATSU logo(PAGE When starting switch is turned to ON position,
30-99) 1 1 1 1 1
KOMATSU logo is displayed for 2 seconds.
Password input(PAGE 30-99) 2
Display of check of breaker mode a After the KOMATSU logo screen is displayed for
(PAGE 30-100) 2 2 seconds, the screen changes to "Password
Display of “check before input" screen, or "Check before starting" screen.
starting”(PAGE 30-100) 3 2 3 2 2
Display of warning after check
before starting(PAGE 30-100) 3
Display of maintenance due time
over(PAGE 30-101) 3
Display of check of working mode
and travel speed(PAGE 30-101) 4 3 4 4 4
Display of standard screen(PAGE
30-101) 5 4 5 5 5
Display of end screen(PAGE 30-101)
Display of operation screen for engine shutdown
secondary switch(PAGE 30-102)
Selection of auto-deceleration(PAGE 30-102)
Selection of working mode(PAGE 30-102)
Selection of travel speed(PAGE 30-103) Password input (PC220-Q180-044-K-02-A)
Operation to stop alarm buzzer(PAGE 30-103) After the KOMATSU logo is displayed, the screen to
Operation of windshield wiper(PAGE 30-103) input the engine start lock password is displayed.
Operation of window washer(PAGE 30-104) a This screen is displayed only when the engine
Operation of air conditioner/heater(PAGE 30-104) start lock function is enabled.
Operation to display camera mode(PAGE 30-104)
a When correct password is input, the screen
Operation to display clock and service meter(PAGE
30-104) changes to "Check before starting" screen.
Check of maintenance information(PAGE 30-105)
Setting and display of user mode (including
KOMTRAX messages for user)(PAGE 30-105)
Display of ECO guidance(PAGE 30-105)
Display of caution monitor(PAGE 30-107)
Display of KDPF regeneration(PAGE 30-107)
Display of action level and failure code(PAGE 30-
110)
O (Special operation)
Function of checking display of LCD (Liquid Crystal
Display)(PAGE 30-111)
Function of checking service meter(PAGE 30-111)
Function of Usage Limitation Setting/ Change
Password(PAGE 30-111)
PC360LC-10 30-99
Electrical system
a The machine monitor has some password

functions other than the engine start lock. Those
functions are independent from one another.
Display of “check before starting” (PC220-Q180-

044-K-04-A)
When the screen changes to the check before
starting screen, the check before starting is
a The following screen may sometimes be
performed for 2 seconds.
displayed instead of the above "Password input"
screen. a If any abnormalities are detected in the check
before starting, the screen changes to "Warning
a If this screen is displayed, call the person
after the check before starting" screen or
responsible for the operation of KOMTRAX in
"Overdue Maintenance" screen.
your Komatsu distributor and ask for remedy.
a If no abnormalities were detected in the check
before starting, display changes to "Working
Mode and Travel Speed Check" screen.
a The monitors (6 monitors) on the screen shows
the items currently subjected to the check before
starting.
Display of check of breaker mode (PC220-Q180-

044-K-03-A)
When the starting switch is turned ON, if the
working mode is set to the breaker mode [B], a
message to inform the operator of starting in the
breaker mode is displayed on the screen.
k If an attachment other than the breaker is Display of warning after check before
used while the working mode is set to the starting (PC220-Q180-044-K-05-A)
breaker mode [B], the machine may move If any abnormalities are detected in the check
unexpectedly or may not operate normally or before starting, the alarm monitor is displayed on
the hydraulic components may be damaged. the screen.
a After operation to check of the breaker mode is a The figure shows how air cleaner clogging
finished, the screen changes to "Display of monitor (a) warns of clogging on air cleaner.
check before starting".
If [No] is selected: Working mode is set to
economy mode [E]
If [Yes] is selected: Working mode is set to
breaker mode [B]
30-100 PC360LC-10
Electrical system
Display of maintenance due time over (PC220- Display of standard screen (PC220-Q180-044-K-08-A)
Q180-044-K-06-A) If the machine monitor starts normally, the standard
If the check before starting detected a maintenance screen is displayed.
item that is near or overdue the set interval, the
maintenance monitor is displayed for 30 seconds to a Service meter (a) or clock is displayed in the top
urge the operator to perform maintenance. center area of the screen (use [F4] to switch the
display of the service meter and clock).
a This screen is displayed only when the
maintenance reminder function is enabled. If the a Right end of the screen displays ECO gauge (b)
remaining time of any item is 30 hours or less, (turn on or off the display in the operator mode).
the yellow icon is displayed. If the remaining
time of any item is 0 hour or less, the red icon is
displayed.
a The maintenance reminder function is enabled
or disabled by using the machine monitor in the
service mode.
Display of end screen (PC220-Q180-044-K-09-A)

When starting switch is turned to OFF position, the
end screen is displayed for 5 seconds.
a Another message may be displayed on the end
screen due to the message display function of
KOMTRAX.
Display of check of working mode and travel
speed (PC220-Q180-044-K-07-A)
If the check before starting is finished normally, the
screen for checking the working mode and travel
speed is displayed for 2 seconds.
a After the "Working mode and travel speed
check" screen is finished, the screen changes to
the "Standard" screen.
PC360LC-10 30-101
Electrical system
Display of operation screen for engine Selection of working mode (PC300-PT5W-100-K-00-A)

shutdown secondary switch (PC220-AKHL-100-K-00-A) Select desired working mode according to the
When you turn the engine shutdown secondary following procedure.
switch to ON position, the "Engine Shutdown 1. While the standard screen is displayed, press
Secondary Switch Activated" screen is displayed on the working mode selector switch, and the
every screen except the end screen. working mode selection screen is displayed.
a The engine shutdown secondary switch is a Following figure shows the working mode
provided in the lower L.H. side corner of the selection screen when "with attachment" is
operator's seat. This switch is used to stop the set. (If "with attachment" is not set in service
engine when it does not stop after the starting mode, attachment mode "ATT/P", "ATT/E"
switch is turned to OFF position. are not displayed.)
When you turn the engine shutdown secondary 2. Operate the function switches or working mode
switch to OFF position, the KOMATSU logo appears selector switch to select the desired working
once and then the display is switched to the mode and enter the selection.
standard screen. Function switch
• [F3]: Moves to lower item
Selection of auto-deceleration (PC220-AF6C-100-K-
00-A) • [F4]: Moves to upper item
While the ordinary screen is displayed, if the auto- • [F5]: Cancels selection and returns to
deceleration switch is pressed, large auto- standard screen
deceleration monitor (a) is displayed for 2 seconds • [F6]: Enters selection and returns to standard
and the setting of the auto-deceleration is changed. screen
Working mode selector switch
a Each time the auto-deceleration switch is • Pressed: Moves to lower item
pressed, the auto-deceleration is changed in the • Kept pressed: Enters selection and returns to
order of [ON] o [OFF] o [ON]. standard screen
a If the auto-deceleration is set to ON, large a If you do not touch any of the function
monitor (a) and auto-deceleration monitor (b) are switches and working mode selector switch
displayed simultaneously. for 5 seconds, the selection is determined
a If the auto-deceleration is set to OFF, auto- and the screen changes to the standard
deceleration monitor (b) goes off. screen.
30-102 PC360LC-10
Electrical system
3. When the ordinary screen is displayed again, a Travel speed setting sequentially changes
large working mode monitor (a) is displayed for 2 between [Lo] o [Mi] o [Hi] o [Lo] in this order
seconds, and then the setting of the working every time the switch is pressed.
mode is changed to the selected mode.
a When large monitor (a) is displayed, the display
a When large monitor (a) is displayed, the of travel speed monitor (b) is changed, too.
display of working mode monitor (b) is
changed, too.
Operation to stop alarm buzzer (PC220-Q576-100-K-

00-A)
<Precautions for selecting breaker mode [B]> While the alarm buzzer is sounding, if the alarm
• If breaker mode [B] is selected, both of the buzzer cancel switch is pressed, the alarm buzzer
control of the hydraulic pump and the setting stops.
of the hydraulic circuit are changed.
• If an attachment other than the breaker is a Even if the alarm buzzer cancel switch is
used, the machine may move unexpectedly pressed, the screen display does not change.
or may not operate normally or the hydraulic
components may be damaged. Operation of windshield wiper (PC220-K751-100-K-00-
A)
• After the breaker mode is selected, the
While the ordinary screen is displayed, if the wiper
screen to confirm the selection of the breaker
switch is pressed, large wiper monitor (a) is
mode is displayed (The buzzer sounds
displayed for 2 seconds and the wiper starts or
intermittently while this screen is displayed).
stops.
• If the setting is confirmed on this screen, the
screen changes to the standard screen. a The window washer does not operate if the
If "No" is selected: Screen returns to working window limit switch is "ON".
mode selecting screen
a The wiper setting changes sequentially between
If [Yes] is selected: Working mode is set to
[INT] o [ON] o [OFF] o [INT] every time you
breaker mode [B]
press the switch.
a When the wiper is set to INT or ON, large
monitor (a) is displayed and the display of wiper
monitor (b) is changed at the same time.
a If the wiper is set to OFF, large monitor (a) is not
displayed and the wiper monitor disappears.
Selection of travel speed (PC220-C6T7-100-K-00-A)

While the standard screen is displayed, if the travel
speed selector switch is pressed, large travel speed
monitor (a) is displayed for 2 seconds and the
setting of the travel speed is changed.
PC360LC-10 30-103
Electrical system
Operation of window washer (PC220-K7DA-100-K-00-

A)
While the ordinary screen is displayed, if the
window washer switch is pressed, the washer fluid
is splashed only while the switch is held down.
a Even if the window washer switch is pressed,
the screen display does not change.
Operation of air conditioner/heater (PC220-K500-

100-K-00-A)
While the standard screen is displayed, if the air
conditioner switch is pressed, "Air-conditioner
Setting" screen is displayed.
a While "Air-conditioner Setting" screen is a If any caution occurs in the camera mode, the
displayed, if you do not touch any switch for 5 corresponding caution monitor is displayed at
seconds, the screen changes to the standard the left top of the screen (excluding the low
screen. hydraulic oil temperature caution).
Operation to display camera mode (PC220-Q16A- a If no control lever is operated for 10 seconds
100-K-00-A) while a failure enough to display user code is
When [F3] is pressed, the multi-display changes to occurring in the camera mode, the screen
the camera image (Set the connection of the returns to the standard screen and displays
camera in the service mode). information about that failure.
a When 2 or more cameras are connected, the
image of one of them or the images of two of
them can be displayed.
a As 2-camera image display [F4] is selected, the
image of camera 1 is displayed on the left side
of the screen and the image of camera 2 is
displayed on the right side.
The image of camera 3 is displayed only singly.
a If 2-camera image display operation is made, the
images are displayed frame by frame at intervals
of approximately 1 second on the right and left
side of the screen.
a Up to 3 cameras can be connected. However, if
Operation to display clock and service
the camera mode is selected, only the image of meter (PC220-Q1MA-100-K-00-A)
camera 1 is always displayed. While the standard screen is displayed, if [F4] is
pressed, the service meter and the clock are
displayed alternately in section (a).
30-104 PC360LC-10
Electrical system
a When selecting the clock display, perform the Setting and display of user mode (including
time adjustment, 12-hour or 24-hour display KOMTRAX messages for user) (PC220-Q1C3-100-K-
02-A)
setting, and summer time setting by using the
user mode functions. To enter the user mode, press [F6] to display the
"User Menu" screen while the standard screen is
displayed.
Check of maintenance information (PC220-Q1C2-

100-K-00-A)
You can check the maintenance information on the a The User Menu has following menus.
maintenance screen by pressing [F6] while the ECO Guidance
maintenance monitor is displayed. Machine setting
When the maintenance monitor does not appear, KDPF regeneration
press [F6] and then press [F1] or [F2]. Then make Maintenance
sure the display is switched to the maintenance Monitor setting
screen.
Check mail
[KOMTRAX message]
• There are 2 types of KOMTRAX message; one
is for the user and the other is for the technician.
• For user:
It denotes the messages transmitted from the
KOMTRAX base station to users. Upon
receiving a message, the message monitor is
displayed on the standard screen. Operate this
"Check mail" when viewing contents of a
message.
• For technician:
It refers to the messages transmitted to the
technicians from the KOMTRAX base station.
a To reset the remaining time after finishing
When a message is received, the standard
maintenance, more operations are necessary.
screen does not display any information relevant
to the message received. To view contents of a
message, operate "Display service message" of
the service menu in the service mode.
Display of ECO guidance (PC220-Q1L3-100-K-00-A)

When the machine is set in a certain operating
condition, the ECO Guidance screen is displayed
automatically to urge the operator to perform the
energy-saving operation.
a "ECO Guidance" screen is displayed when the
following conditions are met while this display
function is set to enabled in operator mode.
a Conditions for display:
• Idle stop guidance
PC360LC-10 30-105
Electrical system
If no lever is operated for a period of at least 5 a The lamp for the E-mode recommendation
minutes and the engine keeps running at idle guidance goes out automatically after 10
speed during this period, the guidance on idle seconds has passed since it appeared, or if
stop is displayed on the monitor. This function the function switch [F5] is pressed.
helps reduce unnecessary fuel consumption by
alerting the operator to stop the engine while
waiting for the next operation, or during a break.
a The lamp for the idle stop guidance goes out
automatically when the lever operation is
resumed, or if the function switch [F5] is
pressed.
• Travel partial recommendation guidance

If machine travel in the travel mode Hi and the
fuel control dial at MAX continues for 2 or more
minutes, the travel partial recommendation
guidance is displayed. When traveling the
machine for a long period of time, moving the
fuel control dial from MAX to a lower position
helps reduce fuel consumption.
• Guidance on deterrence of hydraulic relief
If relieving lasts for 3 or more seconds during a The lamp for the travel partial
operation, guidance on deterrence of hydraulic recommendation guidance goes out
relief is displayed on the monitor. automatically after 10 seconds has passed
since it appeared, or if the function switch
a The lamp for the guidance on deterrence of
[F5] is pressed.
hydraulic relief goes out automatically after
10 seconds has passed since it appeared, or
if the function switch [F5] is pressed.
• Low fuel level guidance

If the amount of time the machine can be
operated that is projected from the remaining
• E-mode recommendation guidance
fuel level and the latest average fuel
If light-load work continues for 10 or more
consumption drops to less than 8 hours, the low
minutes in P- or ATT/P-mode, E-mode
fuel level guidance is displayed.
recommendation guidance is displayed. This
function helps reduce unnecessary fuel
consumption by alerting the operator to turn on
E-mode.
30-106 PC360LC-10
Electrical system
a The lamp for the low fuel level guidance goes Display of KDPF regeneration (PC300-A9H0-251-K-01-
out automatically after 10 seconds has A)
passed since it appeared, or if the function 1. KDPF regeneration
switch [F5] is pressed.
k During the KDPF regeneration, the
exhaust temperature may become higher
than that of the former models. To prevent
being burnt, do not stand near the
exhaust pipe. In addition, to prevent a fire,
do not bring any combustible matter near
the exhaust pipe outlet.
k If there is a thatched roof, dead leaves,

paper, or other combustible matter near
the machine, set KDPF regeneration to
stop to prevent a fire caused by the high-
temperature exhaust gas during the KDPF
regeneration. For the setting procedure,
Display of caution monitor (PC220-Q1FC-044-K-00-A) see the Operation and Maintenance
If an error that is serious enough to display Action Manual.
Level "L01" alarm monitor on the standard screen or KDPF (Komatsu Diesel Particulate Filter)(1) is a
camera mode screen occurs, a large alarm monitor device used to capture soot in exhaust gas and
is displayed on the screen once and is continuously purify the gas. If any soot has accumulated to a
shown in window (a). certain level inside the filter, it is burnt
a On the camera mode screen, the alarm monitor automatically to keep the KDPF performance
flashes at the left upper of the screen when a high. This purification process is called
caution is issued. "regeneration".
If an operation that may lower the filtering
function of the KDPF has continued for a long
period of time, the regeneration may be
performed to protect the KDPF system,
regardless of the accumulated soot.
If an error serious enough to display a alarm monitor

of Action Level [L02], [L03] or [L04] occurs, the
alarm monitor is displayed at the center of the
monitor screen until the error is eliminated.
During the KDPF regeneration, KDPF
regeneration monitor (1) lights up in the standard
screen.
a Even if KDPF regeneration monitor (1) lights
up, the machine does not need to be stopped
and the operator can continue work normally,
as long as the alarm monitor is not displayed
at the center of the standard screen.
PC360LC-10 30-107
Electrical system
The KDPF regeneration is performed The action level goes off in 2 seconds and
automatically in the normal state, but the soot the following standard screen appears.
may not be burnt or the filtering function may not
be recovered sufficiently, depending on the
operating condition. Since KDPF soot
accumulation monitor (2) lights up in this case,
stop the machine in a safe place and perform
the manual stationary regeneration process. For
the execution procedure, see the Operation and
Maintenance Manual.
If the lock lever is set to LOCK position or all

the work equipment control levers are set in
NEUTRAL, the "KDPF Regeneration" screen
is displayed once for every 2 hours after the
occurrence. However, if the manual
stationary regeneration operation is not
performed, the screen returns to the
standard screen after 30 seconds.
2. Manual stationary regeneration
There are 2 levels of monitor displays to request
the manual stationary regeneration, depending
on the degree of emergency.
k If the work is continued while the red

KDPF soot accumulation monitor (2) is
displayed, the KDPF or engine may
encounter a problem. If KDPF soot
accumulation monitor (2) lights up, be
sure to perform the manual stationary
regeneration process.
1) When the degree of emergency is low
If KDPF soot accumulation monitor (2) is a If KDPF soot accumulation monitor (2) is
yellow (Action level (3): L01), the following yellow, stop the work, and then stop the
screen is displayed first. machine in a safe place and perform the
manual stationary regeneration process.
2) When the degree of emergency is high
30-108 PC360LC-10
Electrical system
k If the work is continued without

performing the manual stationary
regeneration and the soot quantity
exceeds the allowable limit, action
level monitor "L04" lights up and the
machine needs to be repaired.
a If KDPF soot accumulation monitor (2)

becomes red, immediately stop the
machine in a safe place and perform the
manual stationary regeneration process.
a If KDPF soot accumulation monitor (2) is

red, the engine maximum output and
maximum speed are limited to protect the
engine and KDPF system.
If KDPF soot accumulation monitor (2) is red
(Action level (3): L03), the following screen is
displayed.
If the lock lever is set to LOCK position or all

the work equipment control levers are set in
NEUTRAL, the "KDPF Regeneration" screen
is displayed after 3 seconds. Then, until the
manual stationary regeneration process is
performed, the "KDPF Regeneration" screen
or the standard screen with the alarm
monitor lighted is displayed automatically
according to the position of the lever.
PC360LC-10 30-109
Electrical system
Display of action level and failure code (PC220-Q1FC-100-K-00-A)

If an abnormality that displays an action level and a a This screen appears only when a trouble (failure
failure code occurs on the standard screen or code) for which an action level is set occurs.
camera mode screen, the alarm monitor lights up.
a The telephone number is displayed only when
the telephone number is registered in the
service mode.
a If multiple troubles occur simultaneously, all the
codes are displayed repeatedly in order.
a Since the information of the displayed failure
code is recorded in the "Abnormality Record" in
the service mode, check the details in the
service mode.
a "Error List" is replaced with the standard screen
automatically after 30 seconds.
a Since "Error List" cannot be displayed from the
If the alarm monitor lights up, press function switch screen on which the camera mode is displayed,
[F5] to display the "Error List". move to "Error List" from the standard screen
• [F1]: Moves selection to next page (screen) side.
(when displayed)
• [F2]: Moves selection to previous page (screen)
(when displayed)
• [F5]: Returns to the standard screen
On the "Error List" screen, the following information
is displayed.
(a): Alarm monitor
(b): Action level (3 digits)
(c): Failure code (5 or 6 digits)
(d): Failure code name
(e): Message
(f): Telephone No. (if registered)
a Remedies requested to operator by displayed action levels (The following table is an excerpt from the
"Operation and Maintenance Manual".)
Degree of Alarm Remedy
urgency Action level Buzzer
monitor
Stop immediately and perform checking and
Q maintenance.
High L04 Q
(Continuous) Ask your Komatsu distributor for testing and repair
services.
Stop work, move machine to safe place, stop it, and
Q perform checking and maintenance.
L03 Q
I (Intermittent) Ask your Komatsu distributor for testing and repair
services.
Stop the work, and then run the engine at medium speed
O Q with no load or stop it. If the condition is not improved,
L02 Q
(Intermittent) ask your Komatsu distributor for testing and repair
services.
Some functions are restricted, but the machine can
L01
operate. After finishing work, perform checking and
Low (For 2 ― Q maintenance.
seconds
Ask your Komatsu distributor to perform testing or
only)
repairs as necessary.
30-110 PC360LC-10
Electrical system
Function of checking display of LCD (Liquid

Crystal Display) (PC-Q1LE-100-K-00-A)
While the standard screen is displayed, if the
numeral input switches or function switches are
operated in the following manner, the entire LCD
screen turns white.
• Switch operations (simultaneous): [4] + [F2]
a When finishing the operation of the switches,
release [F2] first.
a If there is a display error in the LCD, only that
part is indicated in black.
a To return to the former screen, press any one of
the function switches. Function of Usage Limitation Setting/ Change
Reference: An LCD panel, as one of its
Password (PC220-Q19X-100-K-00-A)
Selecting the Usage Limitation Setting displays the
characteristics, sometimes shows black spots
password input screen when you proceed to setting
(spots that remain unlit) and bright spots (spots that
of the circuit breaker or attachment, or maintenance
do not go off).
resetting. Set the usage limitation according to the
If the number of the bright points and black points following procedure.
does not exceed 10, the LCD panel is not faulty or
1. While the standard screen is displayed, perform
defective.
the following operation by using the numeral
input switches.
• Switch operation (Press the switches in order
while pressing [4])
[4] + [5] o [5] o [5]
a This operation of the switches is not
accepted until 10 minutes elapse after the
starting switch is turned to ON position.
Function of checking service meter (PC-Q1MB-

100-K-00-A)
When checking the service meter with the starting
switch in OFF position, operate the numeral input
switches as follows to display only the service meter
section.
• Switch operations (simultaneous): [4] + [1]
a There is some time lag in start of the LCD, so 2. After the "Usage Limitation Password" screen is
hold down the switches until the service meter is displayed, input the current password by using
displayed. the numeral input switches and confirm it by
a If you release one of the switches, the monitor using the function switch.
goes off. • [F5]: Deletes input numbers/ Returns to
Reference: After the machine monitor is used standard screen
continuously over a long period of time, blue points • [F6]: Enters input password
(points that remain lit) may appear on this screen. It a Default password: [000000]
does not indicate that the LCD panel is faulty or
defective. a When the input password is correct, the
screen changes to the next screen.
PC360LC-10 30-111
Electrical system
a When the input password is incorrect, the

message to request inputting the password
again is displayed.
a The password for the Usage Limitation and

the engine start lock password are not
identical.
3. After the "Usage Limitation Setting" screen is 4. Changing a password
displayed, select a setting by using the function After the "Usage Limitation New Password
switch. Input" screen is displayed, input the new
• [F3]: Moves to lower item password by using the numeral input switches
• [F4]: Moves to upper item and confirm it by using the function switch.
• [F5]: Cancels the selection and returns the • [F5]: Deletes input numbers/ Returns the
display to the previous screen display to the preceding screen
• [F6]: Enters selection • [F6]: Enters input password
a Default password: [000000]
a When the input password is correct, the
screen changes to the next screen.
a When the input password is incorrect, the
message to request inputting the password
again is displayed.
a Set a new password of 4 to 6 digits (If it has
only 3 or less digits or has 7 or more digits, it
is not accepted).
Selection of use/non-use of Usage limitation

After the "Usage Limitation ON/OFF" screen is
displayed, select a setting by using the function
switch.
• Non-use: Password input screen is not
displayed
• ON: The password input screen for setting of
the circuit breaker or attachment, or
maintenance resetting appears.
• [F3]: Moves to lower item
• [F4]: Moves to upper item
• [F5]: Cancels the selection and returns the After the "Usage Limitation New Password
display to the previous screen Input" screen is displayed once more, input the
• [F6]: Enters selection new password for the second time by using the
numeral input switches and confirm it by using
the function switch.
• [F5]: Deletes input numbers/ Returns to
standard screen
• [F6]: Enters input password
30-112 PC360LC-10
Electrical system
a If the input password is different from the one

input before, the message to request
inputting again is displayed.
If the standard screen is displayed after the

screen to notify completion of setting is
displayed, the password is changed successfully.
PC360LC-10 30-113
Electrical system
Service mode (PC300-Q194-100-K-00-A) a The menu items which can be selected in the
To change the mode of the machine monitor to the service menu are as follows (including some
service mode from the operator mode, perform the items which need special operations).
following operation.
01 Monitoring / Pre-defined(PAGE 30-115)
This operation is always required when you use the 02 Monitoring(PAGE 30-119)
service mode. Abnormality record (mechanical systems)
1. Check of screen display and operation of (PAGE 30-126)
switches 03
Abnormality record (electrical systems)(PAGE
While the standard screen is displayed, perform 30-127)
the following operation by using the numeral 04 Maintenance Record(PAGE 30-128)
input switches.
05 Maintenance Mode Setting(PAGE 30-129)
• Operation of switches (While pressing [4],
press the switches in order): 06 Phone number entry(PAGE 30-132)
[4] + [1] o [2] o [3] Default (Key-on Mode)(PAGE 30-132)
Default value setting (Unit)(PAGE 30-133)
a This operation of the switches is accepted 07 Default (With/Without Attachment)(PAGE 30-
only while the standard screen is displayed. 134)
Default (Camera)(PAGE 30-135)
Testing (Cylinder Cut-out operation)(PAGE 30-
136)
08 Testing (Regeneration for Service)(PAGE 30-
137)
Testing (KDPF Memory Reset)(PAGE 30-139)
Adjustment (Pump Absorption Torque (F))
(PAGE 30-140)
Adjustment (Pump Absorption Torque (R))
(PAGE 30-140)
Adjustment (Low Speed)(PAGE 30-141)
Adjustment (Attachment Flow Adjustment)
(PAGE 30-142)
2. Selection of service menu 09 Adjustment (Cal F pump swash plate sensor)
When the "Service Menu" screen is displayed, (PAGE 30-144)
the service mode is selected. Select the desired
Adjustment (Cal R pump swash plate sensor)
service menu by using the function switches or (PAGE 30-149)
numeral input switches.
• [F3]: Moves to lower item check)(PAGE 30-150)
• [F4]: Moves to upper item
• [F5]: Returns the display to the standard calibration)(PAGE 30-156)
screen (operator mode)
• [F6]: Validates the selection 10 No Injection(PAGE 30-156)
KOMTRAX Settings (Terminal Status)(PAGE
a If you input a 2-digit code by using the 30-157)
numeral input switches, the corresponding KOMTRAX Settings (GPS and Communication
menu is directly selected. This will allow you 11 Status)(PAGE 30-158)
to validate the selection using [F6]. KOMTRAX Settings screen (Modem Status)
(PAGE 30-159)
12 Service Message(PAGE 30-159)
30-114 PC360LC-10
Electrical system
Monitoring / Pre-defined (PC300-Q1S1-100-K-00-A)

The machine monitor can monitor the condition of
the machine in real time by receiving signals from
various switches, sensors, and actuators installed to
many parts of the machine and the information from
the controllers which control them.
In the monitoring / pre-defined, monitoring items
that are used frequently in daily work are selected
beforehand.
1. Selecting the menu
Select "Monitoring / Pre-defined" on the "Service
Menu" screen.
2. Check of monitoring / pre-defined information

After the "Monitoring / Pre-defined" screen is
displayed, you can check the items displayed in
the troubleshooting support by using the function
switches.
• [F1]: Moves to the next page (screen)
• [F2]: Moves to the previous page (screen)
• [F4]: Selects hold or its releasing
(If hold is selected, a diagonal line is
displayed on the HOLD portion)
• [F5]: Returns to service menu screen
a You can select and check any items not
displayed in "Monitoring / Pre-defined" from
the "Monitoring items."
a If the working mode is changed to breaker

mode [B], the screen to confirm the change
of the setting is displayed as in changing the
working mode on the standard screen.
PC360LC-10 30-115
Electrical system
List of monitoring / pre-defined items (SI unit indicates the default values)
Support screen (1/14) Machine basic items
Unit (Default: SI) Applicable
No. ID Item name equipment
SI Metric Imperial
1 01002 Engine speed r/min rpm rpm ENG
2 04107 Coolant temperature °C °C °F ENG
3 37212 Engine oil switch ENG
4 18400 Intake temperature °C °C °F ENG
5 04401 Hydr. oil temperature °C °C °F PUMP
6 03203 Battery power supply V V V ENG
Support screen (2/14) Fuel injection
SI Metric Imperial
2 47300 KDOC 1 inlet temperature °C °C °F ENG
3 36400 Rail pressure MPa kg/cm2 psi ENG
4 36200 Rail pressure command MPa kg/cm2 psi ENG
5 48000 IMV current A A A ENG
6 48001 IMV current command A A A ENG
Support screen (3/14) EGR,KVGT actuator
SI Metric Imperial
2 48100 Turbo speed r/min rpm rpm ENG
3 18100 EGR Valve Position mm mm in ENG
4 48600 EGR solenoid current mA mA mA ENG
5 48700 KVGT position mm mm in ENG
6 48800 KVGT solenoid current mA mA mA ENG
Support screen (4/14) Engine temperature-related items
SI Metric Imperial
3 04107 Coolant temperature °C °C °F ENG
4 18400 Intake temperature °C °C °F ENG
5 18500 Charge temperature °C °C °F ENG
6 48500 EGR orifice temperature °C °C °F ENG
Support screen (5/14) Air intake/exhaust pressure, etc.
SI Metric Imperial
2 37400 Ambient pressure kPa kg/cm 2 psi ENG
3 36500 Charge pressure-A kPa kg/cm2 psi ENG
4 48300 Exhaust manifold pressure kPa kg/cm 2 psi ENG
6 48200 Mass air flow kg/min kg/min kg/min ENG
30-116 PC360LC-10
Electrical system
Support screen (6/14) Post treatment-related items

SI Metric Imperial
1 47000 KDPF outlet pressure kPa kg/cm2 psi ENG
2 47100 KDPF delta pressure kPa kg/cm 2 psi ENG
3 47200 KDPF 1 outlet temperature °C °C °F ENG
5 47400 KDOC 1 outlet temperature °C °C °F ENG
6 36400 Rail pressure MPa kg/cm2 psi ENG
Support screen (7/14) Engine-related items
SI Metric Imperial
2 37212 Engine oil switch ENG
3 48400 Crankcase pressure kPa kg/cm2 psi ENG
5 36500 Charge pressure-A kPa kg/cm2 psi ENG
Support screen (8/14) F & R pumps basic items
SI Metric Imperial
1 01002 Engine speed r/min r/min r/min ENG
2 01100 F pump pressure MPa kg/cm2 psi PUMP
3 01101 R pump pressure MPa kg/cm 2 psi PUMP
4 01300 PC-EPC sol current (F) mA mA mA PUMP
5 01302 PC-EPC sol current (R) mA mA mA PUMP
Support screen (9/14) F & R pumps application items
SI Metric Imperial
3 01101 R pump pressure MPa kg/cm 2 psi PUMP
4 01137 F pump dispalcement cc/rev cc/rev cc/rev PUMP
5 01139 R pump dispalcement cc/rev cc/rev cc/rev PUMP
Support screen (10/14) F pump application items
SI Metric Imperial
3 01141 Service pressure sensor MPa kg/cm2 psi PUMP
4 01300 PC-EPC sol current (F) mA mA mA PUMP
5 01137 F pump dispalcement cc/rev cc/rev cc/rev PUMP
6 01500 LS-EPC sol current mA mA mA PUMP
PC360LC-10 30-117
Electrical system
Support screen (11/14) R pump application items

SI Metric Imperial
2 01101 R pump pressure MPa kg/cm2 psi PUMP
3 01141 Service pressure sensor MPa kg/cm2 psi PUMP
4 01302 PC-EPC sol current (R) mA mA mA PUMP
5 01139 R pump dispalcement cc/rev cc/rev cc/rev PUMP
6 01500 LS-EPC sol current mA mA mA PUMP
Support screen (12/14) PPC pressure
SI Metric Imperial
2 07400 Boom raise PPC pressure MPa kg/cm2 psi PUMP
3 07500 Boom Lower PPC Pressure MPa kg/cm2 psi PUMP
4 07200 Arm Curl PPC Pressure MPa kg/cm2 psi PUMP
5 07600 Arm Dump PPC pressure MPa kg/cm2 psi PUMP
SI Metric Imperial
2 09002 Swing right PPC pressure MPa kg/cm2 psi PUMP
3 09001 Swing left PPC pressure MPa kg/cm 2 psi PUMP
4 07300 Bucket CURL PPC Pressure MPa kg/cm2 psi PUMP
5 07301 Bucket DUMP PPC pressure MPa kg/cm2 psi PUMP
SI Metric Imperial
2 07102 Travel Fwd LH PPC pressure MPa kg/cm2 psi PUMP
3 07103 Travel Fwd RH PPC pressure MPa kg/cm 2 psi PUMP
4 07104 Travel Rev LH PPC pressure MPa kg/cm2 psi PUMP
5 07105 Travel Rev RH PPC pressure MPa kg/cm2 psi PUMP
30-118 PC360LC-10
Electrical system
Monitoring (PC220-Q19L-100-K-00-A) a Up to 6 monitoring items are selectable at a

The machine monitor can monitor the condition of time. However, the items may not be set up
the machine in real time by receiving signals from to 6 depending on the form of display of the
various switches, sensors, and actuators installed to selected item.
various parts of the machine and the information
from the controllers which is controlling switches,
etc. The monitoring function allows you to select a
desired monitoring item.
1. Selecting menu
Select "Monitoring/Custom" on "Service Menu"
screen.
3. Deciding monitoring items

After selecting monitoring items, execute
monitoring with the function switch or numeral
input switch.
a Execution with function switch: Double click
or keep pressing [F6] (for approximately 2
seconds).
2. Selecting monitoring item
After the "Monitoring Selection Menu" screen is a Execution with numeral input switch: Input
displayed, select items to be monitored by using [99999] and press [F6].
the function switches or numeral input switches. a When monitoring only 2 items, for example,
• [F1]: Moves selection to the left item select them and confirm with [F6]. If [F6] is
• [F2]: Moves selection to the right item pressed once more at this time, monitoring is
• [F3]: Moves selection to the below item executed.
• [F4]: Moves selection to the above item
• [F5]: Clears input numbers/ Returns the a If monitoring items are selected up to the limit
display to the service menu screen number, monitoring is executed
• [F6]: Enters selection automatically.
a In setting of the monitoring, each time

function switch [F2] is pressed, sequential
switching among [ENG] o [KDPF] o
[PUMP] o [MON] o [ENG] takes place in
this order. (Pressing [F1] induces the
sequential switching in the reverse order.)
a Selection with function switches: Select an
applicable equipment by using [F1] or [F2],
select an item by using [F3] or [F4], and then
enter it by using [F6].
a Selection with numeral input switches: Enter
a 5-digit code, and the item of that code is
selected directly. Enter that item by using 4. Performing monitoring
[F6]. After the "Monitoring" screen is displayed,
perform the necessary operation of the machine
a If the color of the selected box changes from and check the monitoring information.
yellow to red, the selection of the item of that
box is entered. a Monitoring information is indicated by value,
ON/OFF, or special display.
PC360LC-10 30-119
Electrical system
a The unit of display can be selected in SI unit,

metric unit, or inch unit with the Default
function in the service mode.
a When the working mode is changed to

breaker mode [B], the screen to confirm the
change of the setting is displayed as in
5. Holding monitoring information changing the working mode on the standard
You can hold and release holding of the screen.
monitoring information by using the function
switches.
• [F4]: Selects hold or releasing hold
(If the Hold is selected, the HOLD portion is
hatched.)
• [F5]: Returns the display to monitoring
selection menu screen
7. Saving of monitoring item

A function switch lets you save and delete the
selected monitoring item.
• [F1]: MEMORY
• [F2]: CLEAR
6. Changing machine setting mode

To change the setting of the working mode,
travel speed, or auto-deceleration during
monitoring, operate the corresponding switch
under the current condition, and the
corresponding mode is selected.
a If the setting is changed during monitoring,
the new setting is held even after the screen
returns to the ordinary screen after
monitoring is finished.
a When you saved a monitoring item, selecting

"Monitoring" again displays the screen that
confirms whether you want to display the
once saved item.
a When an item is saved, it can be displayed
as many times as required unless it is
cleared.
30-120 PC360LC-10
Electrical system
a If another item is saved while having the

previous item saved, the previously saved
item is overwritten by the latest one.
a The saved monitoring item is cleared by
using [F2]. It is also cleared when the
selection is entered by using [F6] in the
following screen.
• KOMTRAX terminal screen
• "With/Without Attachment" screen
• Functional specification screen
• Air conditioner setting screen
PC360LC-10 30-121
Electrical system
Monitoring items table (PC220-Q19L-208-K-00-A)
Code Monitoring item Unit (Default: SI) Equipment

(Displayed on screen) Remarks
No. SI Metric Imperial in charge
01002 Engine speed r/min rpm rpm ENG
04107 Coolant temperature °C °C °F ENG
48000 IMV current A A A ENG
48001 IMV current command A A A ENG
03203 Battery power supply V V V ENG
37212 Engine oil switch ON • OFF ENG
36400 Rail pressure MPa kg/cm2 psi ENG
37400 Ambient pressure kPa kg/cm2 psi ENG
18400 Intake temperature °C °C °F ENG
18500 Charge temperature °C °C °F ENG
Display in absolute
36500 Charge pressure-A kPa kg/cm2 psi ENG value (including
ambient pressure)
48100 Turbo speed r/min rpm rpm ENG
48200 Mass air flow kg/min kg/min lb/min ENG
48300 Exhaust manifold pressure kPa kg/cm2 psi ENG
48400 Crankcase pressure kPa kg/cm 2 psi ENG
18100 EGR Valve Position mm mm in ENG
48500 EGR orifice temperature °C °C °F ENG
48600 EGR solenoid current mA mA mA ENG
48700 KVGT position mm mm in ENG
48800 KVGT solenoid current mA mA mA ENG
36700 Engine Torque Ratio % % % ENG
18700 Engine Output Torque Nm kgm lbft ENG
03000 Throttle position sensor volt V V V ENG
04105 Coolant temp sensor volt V V V ENG
37401 Ambient pressure sensor volt V V V ENG
18401 Intake temp sensor volt V V V ENG
18501 Charge temp sensor volt V V V ENG
36501 Charge pressure sensor volt V V V ENG
36401 Rail pressure sensor volt V V V ENG
48301 Exh manifold press. sens volt V V V ENG
48401 Crankcase pressure sens volt V V V ENG
18101 EGR valve pos sensor volt V V V ENG
48501 EGR orifice temp sens volt V V V ENG
48701 KVGT position sensor volt V V V ENG
17500 Engine power mode - ENG
48900 Engine operation mode - ENG
08402 Selection of droop switch - ENG
31701 Throttle Position % % % ENG
31706 Final throttle position % % % ENG
18600 Inject fueling command mg/st mg/st mg/st ENG
36200 Rail pressure command MPa kg/cm2 psi ENG
37300 Fuel rate (Note 1) l/h l/h gal/h ENG
18800 Water in fuel ON • OFF ENG WIF: Water In Fuel
20216 ECM build version — ENG
20217 Calibration data version — ENG
18900 ECM internal temp °C °C °F ENG
20400 ECM S/N — ENG
47000 KDPF outlet pressure kPa kg/cm2 psi KDPF
30-122 PC360LC-10
Electrical system

47001 KDPF out pressure sensor volt V V V KDPF
47100 KDPF delta pressure kPa kg/cm 2 psi KDPF
47101 KDPF delta press. sensor volt V V V KDPF
47300 KDOC 1 inlet temperature °C °C °F KDPF
47301 KDOC 1 inlet temp sens volt V V V KDPF
47400 KDOC 1 outlet temperature °C °C °F KDPF
47401 KDOC 1 outlet temp sens volt V V V KDPF
47200 KDPF 1 outlet temperature °C °C °F KDPF
47201 KDPF 1 outlet temp sens volt V V V KDPF
47500 Dozing fuel rate l/h l/h gal/h KDPF
47700 Soot level estimation g/L g/L g/gal KDPF
47800 Ash level estimation g/L g/L g/gal KDPF
01601 2nd Eng. Speed Command r/min rpm rpm PUMP
01100 F pump pressure MPa kg/cm2 psi PUMP
01101 R pump pressure MPa kg/cm2 psi PUMP
07400 Boom raise PPC pressure MPa kg/cm 2 psi PUMP
07500 Boom Lower PPC Pressure MPa kg/cm2 psi PUMP
07200 Arm Curl PPC Pressure MPa kg/cm2 psi PUMP
07600 Arm Dump PPC pressure MPa kg/cm 2 psi PUMP
07300 Bucket CURL PPC Pressure MPa kg/cm2 psi PUMP
07301 Bucket DUMP PPC pressure MPa kg/cm2 psi PUMP
09001 Swing left PPC pressure MPa kg/cm 2 psi PUMP
09002 Swing right PPC pressure MPa kg/cm2 psi PUMP
07102 Travel Fwd LH PPC pressure MPa kg/cm2 psi PUMP
07103 Travel Fwd RH PPC pressure MPa kg/cm2 psi PUMP
07104 Travel Rev LH PPC pressure MPa kg/cm 2 psi PUMP
07105 Travel Rev RH PPC pressure MPa kg/cm2 psi PUMP
01137 F pump dispalcement cc/rev cc/rev cc/rev PUMP
01138 F pump sw plate sensor volt V V V PUMP
01139 R pump dispalcement cc/rev cc/rev cc/rev PUMP
01140 R pump sw plate sensor volt V V V PUMP
04401 Hydr. oil temperature °C °C °F PUMP
01300 PC-EPC sol current (F) mA mA mA PUMP
01302 PC-EPC sol current (R) mA mA mA PUMP
01500 LS-EPC sol current mA mA mA PUMP
08000 Merge-divide sol current main mA mA mA PUMP
08001 Merge-divide sol current LS mA mA mA PUMP
01700 Attachment sol current mA mA mA PUMP
03200 Battery voltage V V V PUMP
04402 Hydr. temp. sensor volt V V V PUMP
01602 2nd Eng. Speed Command % % % PUMP
13113 Main Pump Absorb Torque Nm kgm lbft PUMP
15900 Boom Bottom Pressure MPa kg/cm2 psi PUMP
01141 Service pressure sensor MPa kg/cm2 psi PUMP
Swing ON • OFF PUMP
Travel ON • OFF PUMP
Pressure Boom Lower ON • OFF PUMP
01900
Switch 1 Boom Raise ON • OFF PUMP
Arm curl (IN) ON • OFF PUMP
Arm dump (OUT) ON • OFF PUMP
PC360LC-10 30-123
Electrical system

Bucket Curl ON • OFF PUMP
Pressure Bucket Dump ON • OFF PUMP
01901
Switch 2 Service ON • OFF PUMP
Travel steering ON • OFF PUMP
Travel Junction ON • OFF PUMP
Swing brake ON • OFF PUMP
Solenoid Merge-divider
02300 ON • OFF PUMP
valve 1
2-stage Relief ON • OFF PUMP
Travel Speed ON • OFF PUMP
Swing pressure cut off ON • OFF PUMP
Solenoid
02301 Service Return ON • OFF PUMP
valve 2
Variable back press ON • OFF PUMP
Lever Sw. ON • OFF PUMP
02200 Switch Input 1 Swing Release SW. ON • OFF PUMP
Swing brake SW. ON • OFF PUMP
Model select 1 ON • OFF PUMP
02201 Switch Input 2
Overload Alarm ON • OFF PUMP
02202 Switch Input 3 Key switch(ACC) ON • OFF PUMP
02203 Switch Input 4 Lock Lever SW ON • OFF PUMP
Window Limit SW. ON • OFF PUMP
02204 Switch Input 5 P Limit SW. ON • OFF PUMP
W Limit SW. ON • OFF PUMP
20229 Pump controller Ass'y P/N — PUMP
20403 Pump controller Serial No. — PUMP
20230 Pump controller prog. P/N — PUMP
20212 Pump controller prog. version — PUMP
04300 Battery charge volt V V V MON
04200 Fuel level sensor volt V V V MON
Key switch ON • OFF MON
Start ON • OFF MON
Monitor Input Preheating
04500 ON • OFF MON
1
Light ON • OFF MON
Radiator coolant level ON • OFF MON
Aircleaner ON • OFF MON
Monitor Input Eng. oil level
04501 ON • OFF MON
2
Battery charge volt ON • OFF MON
Swing brake Sw. ON • OFF MON
Monitor Input Engine shutdown
04502 secondary switch ON • OFF MON
3
Seat belt Sw. ON • OFF MON
F1 ON • OFF MON
F2 ON • OFF MON
Monitor F3 ON • OFF MON
04503 Function
Switches F4 ON • OFF MON
F5 ON • OFF MON
F6 ON • OFF MON
30-124 PC360LC-10
Electrical system

SW1 ON • OFF MON
SW2 ON • OFF MON
Monitor 1st & SW3 ON • OFF MON
04504 2nd Row
Switches SW4 ON • OFF MON
SW5 ON • OFF MON
SW6 ON • OFF MON
SW7 ON • OFF MON
SW8 ON • OFF MON
Monitor 3rd & SW9 ON • OFF MON
04505 4th Row
Switches SW10 ON • OFF MON
SW11 ON • OFF MON
SW12 ON • OFF MON
SW13 ON • OFF MON
Monitor 5th
04506 SW14 ON • OFF MON
Row Switches
SW15 ON • OFF MON
20227 Monitor Ass'y P/N — MON
20402 Monitor serial No. — MON
20228 Monitor prog. P/N — MON
20200 Monitor prog. version — MON
55300 Aircon compressor status ON • OFF MON
55000 Aircon outside temp. code — MON
55100 Aircon inside temp. code — MON
55200 Aircon mode data(mon) — MON
55201 Aircon mode data(aircon ECU) — MON
Only when
20260 KOMTRAX Ass'y P/N — MON
KOMTRAX is used
— Only when
20418 KOMTRAX Serial No MON
KOMTRAX is used
Only when
20261 KOMTRAX Prog. P/N — MON
KOMTRAX is used
Only when ID key is
20262 ID Key Controller Ass'y P/N — MON
used
Only when ID key is
20419 ID key controller Serial No. — MON
used
Only when ID key is
20263 ID Key Controller Prog. P/N — MON
used
a Listing order of monitoring items in table

The monitoring items are listed in the order of display on the Monitoring selection menu screen for
monitoring item selection.
a Unit
The display unit can be set to SI, meter, or inch as required (select a desired unit from "Unit" of "Default").
mg/st in the display unit is an abbreviation for milligram/stroke.
a Equipment in charge
ENG: The engine controller detects monitoring information.
KDPF: Engine controller is in charge of detecting monitoring information.
PUMP: The pump controller detects monitoring information.
MON: The machine monitor detects monitoring information.
Note 1: Fuel Rate (Code No. : 37300) is theoretical fuel consumption ratio. (Since it is a theoretical value,
there is some differences between the actual fuel consumption ratio).
PC360LC-10 30-125
Electrical system
Abnormality record (mechanical On the "Mechanical Systems" screen, the

systems) (PC220-Q1S2-100-K-00-A) following information is displayed.
The machine monitor logs the past and currently (a) Occurrence order of abnormalities from latest
occurring failures classifying them into the one/Total number of records
mechanical system abnormality and electrical (b): Failure code
system abnormality. (c): Detail of failure
To check the mechanical system abnormality record, (d): Number of occurrences (displayable range:
perform the following procedures. 0 to 65,535 times)
(e): Service meter reading at the first occurrence
a For the failure code list, see "40 Failure code list (f): Service meter reading at the last occurrence
for troubleshooting". • [F1]: Moves selection to next page (screen)
1. Selecting menu (when displayed)
Select "Abnormality Record" on "Service Menu" • [F2] Moves selection to previous page
screen. (screen) (when displayed)
• [F5]: Returns the display to "Abnormality
Record" screen
a If no abnormality is recorded, "No Error" is
displayed.
a In the mechanical systems abnormality
record screen, up to 50 cases currently
stored are displayed.
a If the number of occurrence is 1 (first
occurrence), the service meter reading at the
first occurrence and that at the last
occurrence are the same.
2. Selecting sub menu When the latest service meter reading is
After the "Abnormality Record" screen is recovered, the value at the recovery time is
displayed, select "Mechanical Systems" by displayed, thus the above readings may not
using the function switch or numeral input be the same.
switches. a If [E] is displayed on the left of a failure code,
• [F3]: Moves selection to the below item the abnormality is still occurring or correction
• [F4]: Moves selection to the above item of it is not confirmed.
• [F5]: Returns the display to service menu
screen a For all of the failure codes that the machine
• [F6]: Enters selection monitor can record, see the failure code list.
a When you input a 2-digit code by using the

numeral input switches, the corresponding
item is directly selected. Accordingly, you
may enter the selection by using [F6].
4. Clearing abnormality record

The contents of an abnormality record of the
mechanical system cannot be deleted.
3. Information displayed on "Abnormality Record"

screen
30-126 PC360LC-10
Electrical system
Abnormality record (electrical (a) Occurrence order of abnormalities from latest

systems) (PC220-Q1S3-100-K-00-A) one/Total number of records
The machine monitor logs the past and currently (b): Failure code
occurring failures classifying them into the (c): Detail of failure
mechanical system abnormality and electrical (d): Number of occurrences (displayable range:
system abnormality. 0 to 65,535 times)
To check the electrical system abnormality record, (e): Service meter reading at the first occurrence
perform the following procedures. (f): Service meter reading at the last occurrence
• [F1]: Moves selection to next page (screen)
a For the failure code list, see "40 Failure code list (when displayed)
for troubleshooting". • [F2] Moves selection to previous page
1. Selecting menu (screen) (when displayed)
Select "Abnormality Record" on "Service Menu" • [F3]: Moves selection to the below item
screen. • [F4]: Moves selection to the above item
• [F5]: Returns the display to "Abnormality
Record" screen
a If no abnormality is recorded, "No Error" is
displayed.
a On the electrical systems abnormality record
screen, up to 20 cases currently stored are
displayed.
If the number of abnormality records
increases to 21 or beyond, the latest
occurrence code is displayed and the oldest
one is deleted.
2. Selecting sub menu a If the number of occurrence is 1 (first

After the "Abnormality Record" screen is occurrence), the service meter reading at the
displayed, select "Electrical Systems" by using first occurrence and that at the last
the function switch or numeral input switches. occurrence are the same.
• [F3]: Moves selection to the below item a If [E] is displayed on the left of a failure code,
• [F4]: Moves selection to the above item the abnormality is still occurring or correction
• [F5]: Returns the display to service menu of it is not confirmed.
screen
• [F6]: Enters selection a For all of the failure codes that the machine
monitor can record, see the failure code list.
4. Clearing abnormality record

1) While the "Electrical Systems" screen is
displayed, perform the following operation by
using the numeral input switches.
3. Information displayed on "Abnormality Record"
• Switch operation (Press the switches in
screen
order while pressing [4])
On "Electrical Systems" abnormality record
[4] + [1] o [2] o [3]
screen, the following information is displayed.
PC360LC-10 30-127
Electrical system
a The following figure shows the screen

when an individual item is cleared (it is
slightly different from the screen when all
the item are cleared at once).
2) Check that the display on the screen

becomes the clear mode, then clear the
individual information one by one or all
together by using the function switches.
a If the screen is set in the clear mode, 4) If the screen to notify completion of clearing
graphic mark [CLEAR] is indicated above is displayed and then the "Electrical
[F2]. Systems" (clear mode) screen is displayed,
• [F2]: Clears all items the clearing of the abnormality record is
• [F3]: Moves selection to the below item completed.
• [F4]: Moves selection to the above item a After a while, the screen returns to the
• [F5]: Returns the display to "Abnormality "Electrical Systems" abnormality record
Record" screen screen.
• [F6]: Clears items one by one
a To clear items one by one: Select the item
to be cleared with [F3] or [F4] and press
[F6].
a To clear all items together: Press [F2],
and all the items are cleared, regardless
of selection of the items.
a If [E] is displayed on the left of a failure
code, the clearing operation is accepted
but the item is not cleared.
Maintenance Record (PC220-Q19Z-100-K-00-A)

The machine monitor records the maintenance
information of the filters, oils, etc., which are
displayed and checked by the following operations.
When the maintenance is performed, if the data are
reset in the operator mode, the number of the times
of maintenance is recorded in this section.
1. Selecting menu
Select "Maintenance Record" on "Service Menu"
screen.
3) After the "Electrical Sys. Error Reset" screen
is displayed, operate the function switches.
• [F5]: Returns to Electrical Systems
abnormality record screen
(clear mode)
• [F6]: Executes clearing
30-128 PC360LC-10
Electrical system
3. Items displayed on Maintenance Record screen

The following information is displayed.
(a): Maintenance items
(b): Number of replacements up to now
(c): Service meter reading (SMR) at the last
replacement
2. Selecting maintenance record item

After the "Maintenance Record" screen is
displayed, select an item of which the setting is
to be checked by using the function switches or
• [F1]: Moves selection to next page (screen)
• [F2]: Moves selection to previous page
(screen) Maintenance Mode Setting (PC220-Q1F1-100-K-00-A)
• [F3]: Moves selection to the below item The actuating condition of the maintenance
• [F4]: Moves selection to the above item reminder function in the operator mode can be set
• [F5]: Returns the display to service menu and changed by using this menu.
screen
• To enable or disable the function
a You may enter a 2-digit code by using the • Change set replacement interval (by item)
numeral input switches to select the item of • Initialize all of set change intervals
that code. 1. Selecting menu
Select "Maintenance Mode Setting" on "Service
Menu" screen.
a The following items can be selected in the

maintenance record.
2. Selecting sub menu
49 Air cleaner cleaning/change
After the "Maintenance Mode Setting" screen is
01 Engine oil change displayed, select an item of which the setting is
02 Engine oil filter change to be changed by using the function switches or
03 Fuel main filter change numeral input switches.
41 Fuel prefilter change • [F1]: Moves selection to next page (screen)
04 Hydraulic oil filter change • [F2]: Moves selection to previous page
05 Hydraulic tank breather change (screen)
07 Damper case oil check and refill • [F3]: Moves selection to the below item
08 Final drive case oil change interval • [F4]: Moves selection to the above item
• [F5]: Returns the display to service menu
09 Machinery case oil change
screen
10 Hydraulic oil change
• [F6]: Enters selection
47 KCCV filter change
48 KDPF filter cleaning
PC360LC-10 30-129
Electrical system

4. Setting of Maintenance Notice Time Setting

After selecting "Maintenance Notice Time
Setting", if the screen is displayed, set with the
function switches.
a The following items can be selected on the

Maintenance Mode Setting screen.
00 Maintenance mode change
49 Air cleaner cleaning/ change Interval
01 Engine oil change interval
02 Engine oil filter change interval
03 Fuel main filter change interval
41 Fuel prefilter change interval
04 Hydraulic oil filter change interval
05 Hydraulic tank breather change interval
07 Damper case oil check and refill interval
08 Final drive oil change Interval • Default value: Maintenance notice time set
09 Swing machinery oil change interval on the machine monitor (Recommended by
10 Hydraulic oil change interval the manufacturer and not changeable).
• Set value: Maintenance interval that can be
99 Returns all to Default Values
freely set. Maintenance reminder function
3. Setting of maintenance mode change works according to this set time in operator
After selecting "Maintenance Mode Change" mode (the time increases or decreases in
and the screen is displayed, select the desired multiples of 10 hours).
setting by using the function switches. • [F3]: Decreases set value
• ON: Functions of all maintenance items • [F4]: Increases set value
become effective in operator mode. • [F5] Cancels contents of setting before entry
• OFF: Functions of all maintenance items and returns to the "Maintenance Mode
becomes ineffective in operator mode Change" screen
• [F3]: Moves selection to the below item • [F6]: Enters setting and returns to
• [F4]: Moves selection to the above item Maintenance mode setting screen
• [F5] Cancels selection and returns to the
"Maintenance Mode Change" screen
• [F6]: Enters selection and returns to
a Even if ON/OFF of each item has been set, if
the above setting is changed, it overrides the
individual setting.
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Electrical system
5. Setting of each maintenance item • [F5] Cancels contents of setting before entry
Select each maintenance item. After the screen and returns to the "Maintenance Mode
is displayed, set the item by using the function Change" screen
switches. • [F6]: Enters setting and returns to
• ON: Function of the selected individual "Maintenance Mode Change" screen
maintenance item becomes effective in
a When you enter by using [F6] and return to
operator mode.
the "Maintenance Mode Setting" screen by
• OFF: Function of the selected individual
using [F5] , your setting is validated.
maintenance item becomes ineffective in
operator mode. a If the set value of an item of which
• [F3]: Moves selection to the below item maintenance reminder function is set to "ON"
• [F4]: Moves selection to the above item is changed after 1 operating hour or more
• [F5]: Cancels selection and returns to the from the setup, the change is recognized as
"Maintenance Mode Change" screen a reset of the remaining time.
• [F6]: Enters selection and returns to
7. Function to return all of the values to Default

Values
6. Setting of set value of each maintenance item After selecting "All Default Value" and the
Select the set value of each maintenance item. screen is displayed, select the desired setting by
After the screen is displayed, set the value by using the function switches.
using the function switches.
• If the operation for this function is executed,

• Default value: Maintenance notice time set the set values of all the maintenance items
on the machine monitor (Recommended by are returned to the default values.
the manufacturer and not changeable). • [F5]: Returns the display to "Maintenance
• Set value: Maintenance interval that can be Mode Setting" screen
freely set. Maintenance reminder function • [F6]: Executes initialization
works according to this set time in operator
a A while after [F6] is pressed, the initialization
mode (the time increases or decreases in
completion screen is displayed. Then, when
multiples of 25 hours).
the "Maintenance Mode Setting" screen is
• [F3]: Decreases set value
displayed, initialization is completed.
• [F4]: Increases set value
PC360LC-10 30-131
Electrical system
Phone number entry (PC220-Q19A-110-K-00-A) a Up to 14 digits can be input from the left.
The telephone number, which is displayed together Input nothing in the surplus places.
with the "Occurred error list" in the operator mode, a If an input numeral is wrong, move the cursor
can be input and changed according to the following (orange background) to that digit and
procedure. overwrite it with the correct numeral.
If a telephone number is not input with this function,
a If [F6] is pressed without inputting a digit,
no telephone number is displayed in the operator
there is not information of telephone No.
mode.
Accordingly, no telephone No. is displayed in
1. Selecting menu the operator mode.
Select "Phone Number Entry" on the "Service
Menu" screen.
Default (Key-on Mode) (PC220-Q1F2-100-K-00-A)

2. Registering and changing phone number Use the menu of Default to check or change various
After the "Phone Number Entry" screen is settings of the machine monitor and machine.
displayed, register or change the phone number
Use the sub menu of "key-on Mode" to set the
by using the function switch or numeral input
working mode selected and displayed on the
switches. machine monitor when the starting switch is turned
• [F2]: Deletes all input digits to ON position.
• [F3]: Moves the input position to the next left
place (if not blank) 1. Selecting menu
• [F4]: Moves the input position to the next Select "Default" on "Service Menu" screen.
right place (if not blank)
• [F5]: Resets input digit/Returns the display to
the service menu screen
• [F6]: Validates the entry
30-132 PC360LC-10
Electrical system
• [F6]: Enters selection and returns the display

to Default screen
a Factory default is, "Mode at Previous Key-
off".
a If "With Attachment" is not selected, selection
of the Attachment /P-Mode and Attachment/
E-mode is disabled.
a If you change the setting to "Without
attachment" when Attachment/P-mode [P] or
Attachment/E-mode is selected, Power
mode [P] is displayed when the starting
2. Selecting sub menu switch is turned to ON position.
After the "Default" screen is displayed, select a If the engine is stopped with the working
"Key-on Mode" by using the function switch or mode set to breaker mode [B] in the operator
numeral input switches. mode, Breaker Mode [B] is always displayed
a Select this item similarly to an item on the when the starting switch is turned to ON
"Service Menu" screen. position, regardless of the above setting.
3. Selecting mode
Default value setting (Unit) (PC220-Q1F3-100-K-00-A)
After the "Key-on Mode" screen is displayed,
Use the menu of "Default" to check or change
select the mode to be set by using the function
various settings of the machine monitor and
switches.
machine.
• Power mode: [P] is displayed when the
starting switch is set to ON position The unit selecting function is used to select the unit
• Economy mode: [E] is displayed when the of the data to be displayed in monitoring, etc.
starting switch is set to ON position 1. Selecting menu
• Lifting Operation Mode: [L] is displayed when Select "Default" on "Service Menu" screen.
the starting switch is turned to ON position.
• Breaker Mode: [B] is displayed when the
• Attachment/P-mode: [ATT/P] is displayed
when the starting switch is set to ON
position.
• Attachment/E-mode: [ATT/E] is displayed
when the starting switch is set to ON
position.
• Mode at Previous Key-off: Final mode in
previous operation is displayed when the
• [F3]: Moves selection to the below item
• [F4]: Moves selection to the above item 2. Selecting sub menu
• [F5]: Cancels selection and returns the After the "Default" screen is displayed, select
display to Default screen "Unit" by using the function switch or numeral
input switches.
PC360LC-10 30-133
Electrical system
a Select this item similarly to an item on the

"Service Menu" screen.

After the "Default" screen is displayed, select
3. Selecting unit "With/Without Attachment" by using the function
After the "Unit" screen is displayed, select the switch or numeral input switches.
unit to be set by using the function switches. a Select this item similarly to an item on the
• [F3]: Moves selection to the below item "Service Menu" screen.
• [F5]: Cancels selection and returns the
display to Default screen
• [F6]: Enters selection and returns the display
to Default screen
a Factory default is the “SI Unit”.
3. Selecting With/Without
After the "With/Without Attachment" screen is
displayed, select a setting by using the function
switch.
• Without Attachment: When attachment is not
installed
• With Attachment: When attachment is
Default (With/Without Attachment) (PC220-Q1F4- installed
100-K-00-A) • [F3]: Moves selection to the below item
Use the menu of Default to check or change various • [F4]: Moves selection to the above item
settings of the machine monitor and machine. • [F5]: Cancels selection and returns the
Use the sub menu of "With/Without Attachment" to display to Default screen
configure attachment setting when the attachment • [F6]: Enters selection and returns the display
is installed or removed. to Default screen
1. Selecting menu a When an attachment is installed, if this
Select "Default" on "Service Menu" screen. setting is not configured correctly, the
attachment setting in the operator mode
cannot be performed. As a result, the
attachment may not work normally or the
hydraulic components may be damaged.
30-134 PC360LC-10
Electrical system
• Use: Image from connected camera is

displayed as a normal image.
• [Я]: Reverse images (mirror images, used for
rearview monitor) are displayed.
• [R]: Normal images (visual images, used for
front monitor or side monitor) are displayed.
• [F5]: Cancels the changes prior to
confirmation and returns to the Default
screen
• [F6]: Enters selection in each line
a You cannot switch camera 1 between [Я] and
Default (Camera) (PC220-Q1F6-100-K-00-A) [R].
Use the menu of Default to check or change various a When you enter selection in each line with
settings of the machine monitor and machine. [F6] and return to the "Default" screen with
Use the sub menu of "Camera" to configure camera [F5], your setting is validated.
setting when the camera is installed or removed.
a When a camera is connected, if it is not set
1. Selecting menu normally with this function, the graphic mark
Select "Default" on "Service Menu" screen. of camera is not displayed at [F3] in the
operator mode. Accordingly, the image of the
camera cannot be used.
a When the camera is installed, check that the
right and left portions of the displayed image
are correct.

After the "Default" screen is displayed, select
"Camera" by using the function switch or
3. Selecting camera setting

After the "Camera" screen is displayed, select a
setting by using the function switch.
• Not Use: Camera is not used
PC360LC-10 30-135
Electrical system
1. Selecting menu
Select "Diagnostic Tests" on "Service Menu"
screen.
a If 2 or more cameras are connected, be sure

to set the use of them from camera 1 in
order.
a The simultaneous display function of 2 After the "Diagnostic Tests" screen is displayed,
images becomes effective when camera 1 select "Cylinder Cut-out" using the function
and camera 2 are set for use. switch or numeral input switches.
3. Selecting cylinder to be cut-out

After the "Cylinder Cut-out" screen is displayed,
select a cylinder to be cut out by using the
function switches.
• [F1]: Moves selection to the left item
• [F2]: Moves selection to the right item
• [F4]: Selects hold or releasing hold
(If the Hold is selected, the HOLD portion is
hatched.)
• [F5]: Returns the display to "Diagnostic
Tests" screen
Testing (Cylinder Cut-out operation) (PC220- • [F6]: Enters selection
AD00-34F-K-00-A)
In the machine monitor, the cylinder cut-out mode a This operation may be performed while the
operation and the KDPF regeneration operation can engine is running.
be executed as well as their cancellation. a When [F6] is pressed, if background (a) of
Cylinder cutout mode operation means to run the the selected cylinder No. becomes white, the
engine with one or more fuel injectors disabled cylinder is cut out.
electrically to reduce the number of effective
a If the machine monitor cuts out a cylinder but
cylinders. This operation is used to identify a
the engine controller cannot cut out that
cylinder that does not output power normally
cylinder, the background (a) of the cylinder
(combustion in it is abnormal).
number becomes yellow.
30-136 PC360LC-10
Electrical system
a One or more cylinders can be cut-out.

a During the Cylinder Cut-out operation, the
auto-deceleration function can be enabled.
When the auto-deceleration is set to ON,
auto-deceleration monitor (b) is displayed.
[Reference]
• If a normally operating cylinder is cut out, the
following phenomena occur.
1) Lowering of engine speed
2) Fuel Inject Command (quantity) increases.
• If the engine is running at near high idle,
4. Releasing cut-out cylinder however, the engine speed may not lower for
When changing a cylinder to be cut out or when the reason of engine control.
Cylinder Cut-Out operation is finished, select a • In this case, lower the engine speed with the
cut-out cylinder to be reset with the function fuel control dial and judge by increase of the
switches. injection rate command.
a This operation may be performed while the Testing (Regeneration for Service) (PC220-A9H0-
engine is running. 252-K-00-A)
a When [F6] is pressed, if background (a) of In the machine monitor, the cylinder cut-out mode
the selected cylinder No. becomes blue, the operation and the KDPF regeneration operation can
cylinder is reset. be executed as well as their cancellation.
Active regeneration for service refers to the method
a If the machine monitor releases a cut-out of burning soot by performing the KDPF
cylinder but the engine controller cannot regeneration, regardless of the soot accumulation.
release the cut-out cylinder, the background
(a) of the cylinder number becomes red. 1. Selecting menu
a The cut-out cylinder mode operation is not screen.
automatically released after the screen
returns to the operator mode. Accordingly, be
sure to perform the releasing operation after
the cylinder cut-out mode operation is
finished.
5. Holding displayed data
Each time [F4] is pressed during the Cylinder
Cut-Out operation, the displayed data is newly
held (c) (the real-time data is kept displayed on
the left side).
While the data is held, if [F4] is pressed, the data
holding function is reset.
a The holding function is available for a
cylinder, regardless of whether it is cut out or 2. Selecting sub menu
not. After the "Diagnostic Tests" screen is displayed,
select "Regeneration for Service" by using the
function switch or numeral input switches.
PC360LC-10 30-137
Electrical system
a While the KDPF regeneration status is in the a Before performing the manual stationary
manual stationary regeneration or stopped, regeneration, be sure the surrounding
"Regeneration for Service" cannot be environment is safe, no people and no
selected. combustibles are in the area. When you
have to move the machine again for the
sake of security, move it to a safe place
and repeat the operation from the start.
a The active regeneration for service
automatically stops in 40 minutes.
However, if the regeneration is started
with the soot accumulation of
approximately 4 g/liter and if the soot
accumulation still remains at above 1.9 g/
liter after 40 minutes from the start, the
operation is switched to the automatic
regeneration. The regeneration is
continued until the soot accumulation
3. Setting regeneration for service decreases to 1.9 g/liter.
When "Regeneration for Service" screen is
displayed, the following informations are
displayed corresponding to the KDPF
regeneration condition. Set the KDPF
regeneration according to the given messages.
(a): Soot accumulation level
(b): Regenerating condition of KDPF
(c): Selectable items
(d): Message
a The screen displays "Monitoring

Selection Menu" screen by the following
switch operations while the regeneration
for service is in progress.
• Switch operation (While pressing [4],
press other switches in order): [4] + [1]
o [2] o [3]
To return to the regeneration for
1) KDPF active regeneration (manual stationary service screen from the monitoring
regeneration) screen, press [F5].
Select "Manual Stationary Regeneration" on For the monitoring procedures, see
"Regeneration for Service" screen. "Monitoring" of "Service mode".
• [F5]: Returns the display to "Diagnostic 2) Finishing regeneration
Tests" screen After the active regeneration for service is
• [F6]: Executes manual stationary completed, "Regeneration completed" is
regeneration displayed on the screen.
a Active regeneration for service can be
performed only when the lock lever is in
LOCK position and the fuel control dial is
the low idle (MIN) position.
30-138 PC360LC-10
Electrical system
3) Stopping of regeneration 2. Selecting sub menu

If [F6] is pressed during manual stationary After the "Diagnostic Tests" screen is displayed,
regeneration, "Stop manual stationary select "KDPF Memory Reset" by using the
regeneration?" is displayed on the screen. function switch or numeral input switches.
Validate the stop by using the function switch.
• [F5]: Does not disable regeneration
(Continue stationary manual
regeneration)
• [F6]: Stops regeneration
3. Setting KDPF Memory Reset

Select an item to be reset, on the "KDPF
Memory Reset" screen.
Testing (KDPF Memory Reset) (PC220-A9H0-271-K-
00-A) • [F4]: Moves selection to the above item
In the machine monitor, the cylinder cut-out mode • [F5]: Returns the display to "Diagnostic
operation and the KDPF regeneration operation can Tests" screen
be executed as well as their cancellation. • [F6]: Enters selection
KDPF Memory Reset means resetting the KDPF
information stored on the machine. It is performed
when cleaning or replacement of KDPF is done, or
when the engine controller is replaced.
1. Selecting menu
screen.
After "Do you want to reset?" is displayed,

validate the reset by using the function
switch.
• [F5]: Returns the display to the previous
screen
PC360LC-10 30-139
Electrical system
• [F6]: Executes reset
3. Selecting pump absorption torque setting

After the "Pump Absorption Torque (F)" screen
When the reset is finished properly, "Reset
is displayed, select the desired value at the right
completed" is displayed on the screen. If the
side by using the function switches.
reset is not finished properly, "Reset failed" is
• Set value: For actual torque adjustment
displayed on the screen.
value, see table
a Perform the KDPF replacement reset • [F3]: Increases set value
after replacing the KDPF. • [F4]: Decreases set value
• [F6]: Confirms setting and returns to
a Perform the KDPF cleaning reset after
Adjustment screen
cleaning the KDPF.
a The 3-digit number in the left column do not
a Perform the KDOC replacement reset
change since it is the code of this function.
after replacing the engine controller.
Adjustment (Pump Absorption Torque

(F)) (PC220-C201-27E-K-00-A)
You can make various adjustments related to the
machine with the machine monitor.
The sub menu of Pump Absorption Torque is used
to finely adjust the absorption torque of the
hydraulic pump.
1. Selecting menu
Select "Adjustment" on "Service Menu" screen.
a Relationship between set value and torque

adjustment value
Torque adjustment
Code Set Value
value
000 +39.2 Nm {+4 kgm}
001 +29.4 Nm {+3 kgm}
002 +19.6 Nm {+2 kgm}
003 +9.8 Nm {+1 kgm}
021 004 0 Nm {0 kgm}
005 -9.8 Nm {-1 kgm}
After the "Adjustment" screen is displayed, 006 -19.6 N {-2 kgm}
select "Pump Absorption Torque (F)" by using 007 -29.4 Nm {-3 kgm}
the function switch or numeral input switches. 008 -39.2 Nm {-4 kgm}
a Select this item similarly to an item on the Adjustment (Pump Absorption Torque
"Service Menu" screen. (R)) (PC220-C202-27E-K-00-A)
You can make various adjustments related to the
machine with the machine monitor.
30-140 PC360LC-10
Electrical system
The sub menu of Pump Absorption Torque (R) is a The 3-digit number in the left column do not
used to finely adjust the absorption torque of the change since it is the code of this function.
rear hydraulic pump.
1. Selecting menu
Select "Adjustment" on "Service Menu" screen.
a Relationship between set value and torque

adjustment value
2. Selecting sub menu Torque adjustment

Code Set Value
value
After the "Adjustment" screen is displayed,
000 +39.2 Nm {+4 kgm}
select "Pump Absorption Torque (R)" by using
001 +29.4 Nm {+3 kgm}
the function switch or numeral input switches.
002 +19.6 Nm {+2 kgm}
a Select this item similarly to an item on the 003 +9.8 Nm {+1 kgm}
"Service Menu" screen. 0 Nm {0 kgm}
022 004
005 -9.8 Nm {-1 kgm}
006 -19.6 Nm {-2 kgm}
007 -29.4 Nm {-3 kgm}
008 -39.2 Nm {-4 kgm}
Adjustment (Low Speed) (PC300-Q1F8-100-K-00-A)

The machine monitor allows for adjustment of
various items related to the machine with the
machine monitor.
The sub menu of Low Speed is used to finely adjust
the travel speed at Low setting.
3. Selecting pump absorption torque setting Select "Adjustment" on the "Service Menu"
After the "Pump Absorption Torque (R)" screen screen.
is displayed, select the desired value at the right
side by using the function switches.
• Set value: For actual torque adjustment
value, see table
• [F3]: Increases set value
• [F6]: Confirms setting and returns to
Adjustment screen

select "Low speed" using the function switches
or numeral input switches.
PC360LC-10 30-141
Electrical system
a Select this sub menu as in the case of The sub menu of "Attachment Flow Adjustment"
selecting a menu on the "Service Menu" allows for fine adjustment of the oil flow to the
screen. attachment during combined operation.
Select "Adjustment" on the "Service Menu"
screen.
3. Selecting low speed

After the "Low Speed" screen for setting is
displayed, select a set value in the right column
by using the function switches. 2. Selecting sub menu
• Set value code: For the actual travel speed After the "Adjustment" screen is displayed,
at Low setting, see the table shown in the select "Attachment Flow Adjustment" by using
next page. the function switches or numeral input switches.
• [F4]: Increases set value a Select this sub menu as in the case of
• [F6]: Confirms setting and return to the selecting a menu on the "Service Menu"
adjustment menu screen screen.

3. Selecting set value code for oil flow distribution

After the screen of "Attachment Flow
Adjustment" is displayed, select a set value in
a Relationship between set value and travel the right column by using the function switches.
speed at Low setting • Set value code: For actual distribution of oil
flow, see the table shown below
Travel speed at • [F3]: Increases set value
Code Set value code
Low • [F4]: Decreases set value
000 3.2 km/h • [F6]: Confirms setting and return to the
001 2.8 km/h adjustment menu screen
020
002 3.0 km/h
003 3.4 km/h
Adjustment (Attachment Flow
Adjustment) (PC300-Q1F9-100-K-00-A)
machine monitor.
30-142 PC360LC-10
Electrical system
a Relationship between set value and

distribution of oil flow to attachment
Set value Distribution of flow to
Code
code attachment
000 50%
001 70%
037
002 100%
003 40%
PC360LC-10 30-143
Electrical system
Adjustment (Cal F pump swash plate sensor) (PC300-C3W9-273-K-00-A)

The machine monitor allows for adjustment of various items related to the machine with the machine monitor.
The F pump swash plate sensor calibration sub menu is used to calibrate the sensor installed on the actual
machine to eliminate deviation of the sensor signal made when the front pump swash plate sensor is
removed and installed or replaced with new one.
a The pump swash plate sensor needs to be adjusted in the following cases.
Calibration of front pump Calibration of rear pump

swash plate sensor swash plate sensor
Removal and installation or replacement of front pump
Necessary ―
swash plate sensor
Removal and installation or replacement of rear pump
― Necessary
swash plate sensor
Replacement of main pump assembly Necessary Necessary
Replacement of pump controller Necessary Necessary
Adjustment and disassembly of front pump PC valve Necessary ―
Adjustment and disassembly of rear pump PC valve ― Necessary
a Before calibrating the pump swash plate sensor,

Test the pump swash plate sensor to
Check that the pump swash plate sensor is normal.
a A rough flow of calibration of the pump swash plate sensor is as follows.
In adjustment menu of service menu 1. Preparation for calibration
Before starting calibration, set the machine
• Hydraulic oil temperature: 50°C
• Working mode: P mode
screen.

select "Cal F pump swash plate sensor" by
using the function switches or numeral input
switches.
30-144 PC360LC-10
Electrical system
4. Calibration of front pump swash plate sensor for 3) When the speed of the track running idle is
the maximum angle stabilized, hold down [F1] of the machine
1) After the "Cal F pump swash plate sensor monitor to start calibration.
max" is displayed, calibrate the front pump A bar is displayed during calibration.
swash plate sensor for the maximum angle Keep running the track idle until calibration is
by running track idle off the ground and finished.
operating the function switches.
[F1]: START
[F2]: CLEAR
[F5]: Returns to the adjustment screen
[F6]: Confirms setting
4) Calibration is finished successfully, "OK" is

displayed for the State of adjustment to show
that calibration for the maximum angle is
completed.
Press [F6] to go to calibration for the
2) Raise the left track off ground by using the minimum angle.
work equipment and move the left travel
lever to the stroke end to run the left track
idle off the ground.
• Fuel control dial: Max.
• Right travel lever: Max.
Travel direction may be set in either of
forward and reverse.
• Swing lock switch may be set in either of
ON and OFF.
Either will do.
k Provide a enough work space to run

the track idle off the ground.
If calibration is finished unsuccessfully, "NG"
k While taking care of safety around the is displayed for the State of adjustment and
machine, run the raised track idle. the failure cause code is displayed. Referring
to the failure cause codes in Table 1, find out
and remove the cause and repeat calibration.
PC360LC-10 30-145
Electrical system
4) Calibration is finished successfully, "OK" is

a The calibration value can be initialized by
displayed for the State of adjustment to show
holding down CLEAR button [F2].
that calibration for the minimum angle is
If the calibration value is initialized, completed.
"READY" is displayed for the State of Press [F6] to return to the Adjustment screen.
adjustment on the screen.
5. Calibration of front pump swash plate sensor for
the minimum angle
1) After the "Cal F pump swash plate sensor
min" is displayed, set all the levers in neutral
and
Perform calibration on the Min. side of the
front pump swash plate sensor with the
function switches.
[F1]: START
[F2]: CLEAR
[F5]: Returns to the adjustment screen
[F6]: Confirms setting
If calibration is finished unsuccessfully, "NG"
is displayed for the State of adjustment and
the failure cause code is displayed. Referring
to the failure cause codes in Table 1, find out
and remove the cause and press [F6] to
repeat the calibration for the minimum angle.
2) Wait under the following conditions:

• All levers: NEUTRAL
Fuel control dial may be at any position.
3) Hold down [F1] of the machine monitor to
start calibration.
A bar is displayed during calibration.
Keep all the levers in NEUTRAL until
calibration is finished. a The calibration value can be initialized by
holding down CLEAR button [F2].
If the calibration value is initialized,
"READY" is displayed for the State of
adjustment on the screen.
30-146 PC360LC-10
Electrical system
Table 1. Failure cause codes

Calibration failure cause codes (Displayed in descending order of priority)
Object
MIN MAX
Cause Description Remedy
Calibration Calibration Pump
code
of swash of swash Calibration
plate plate
A-1 q q q Engine speed signal is 0 rpm Check that engine is started
Hydraulic oil temperature is Check hydraulic oil
A-2 q q q temperature (Min. 45 °C)
low
Check hydraulic oil
Hydraulic oil temperature is temperature (Calibration of
A-3 q q q high swash plate: Max. 85°C,
Pump calibration: Max. 55°C)
A-4 q q q Engine overheats Check for overheat
Pump pressure sensor (F, R) Perform troubleshooting for
A-6 q q q pump pressure sensor
is defective
Pump swash plate (F, R) Perform troubleshooting for
A-7 q q —
sensor is defective pump swash plate sensor
Arm IN PPC pressure sensor Perform troubleshooting of
A-8 — — q
is defective arm IN PPC pressure sensor
— — PC-EPC abnormality Perform troubleshooting of
A-9 q
PC-EPC
Defective CAN communication Perform troubleshooting of
A-A — — q (Eng, Monitor, Pump) CAN
Perform troubleshooting of
— — Bucket CURL PPC pressure
A-B q bucket CURL PPC pressure
sensor is defective
sensor
Pump pressure of calibrated Perform troubleshooting of
B-1 q — —
pump is above standard value relief valve and pump
Set all control levers to
B-3 q — — Lever is not in NEUTRAL NEUTRAL position.
C-1 — q —
pump is below standard value relief valve and pump
— — Travel speed setting is not Hi Set travel speed switch to Hi
C-2 q
from the monitor.
Fuel control dial is not set to Set fuel control dial to Max.
C-3 — q q Max. position position.
Set travel lever to full stroke
C-4 — q — Both tracks are running and work equipment lever to
neutral.
Check the service flow rate
Oil flow from 2 pumps are not (Normally oil from the pump is
C-5 — q —
divided diverted when the travel circuit
is relieved singly)
Travel PPC pressure sensor is Perform troubleshooting of
C-6 — q —
defective travel PPC pressure sensor
— — Travel PPC pressure is below
C-7 q Set travel lever to full stroke.
standard value
Arm IN when the arm IN circuit
relieved
PPC pressure is below the
E-1 — — q Set arm lever to full stroke.
specified level or arm IN
PPC pressure sensor is out of
the normal range
Pump pressure (F, R) is out of Perform troubleshooting of
E-2 — — q the specified range relief valve and pump
PC360LC-10 30-147
Electrical system
Object
MIN MAX
code
plate plate
Engine speed is out of the Set the engine to Hi idle
E-3 — — q specified range speed.
Engine torque is out of the Perform troubleshooting of
E-4 — — q specified range engine and pump
PC-EPC current is out of the Perform troubleshooting of
E-5 — — q specified range PC-EPC current
When bucket CURL circuit is
relieved, bucket CURL PPC
pressure is below the
E-6 — — q Set bucket lever to full stroke.
specified value or bucket
CURL PPC pressure sensor is
out of the normal range.
Working mode is not set to [P] Set working mode is to [P] or
E-7 — — q or [ATT/P] [ATT/P].
Swing emergency stop switch Set swing emergency stop
E-8 — — q is not set to ON position switch to ON position.
Swing lock switch is not set to Set swing lock switch to ON
E-9 — — q ON position position.
Air conditioner is set to ON Set air conditioner to OFF
E-A — — q position position.
Output voltage of pump swash
FF q q — plate sensor is out of
swash plate sensor
calibration range
KDPF regeneration is
G-1 — — q End KDPF regeneration.
underway
(*1) When the sensor voltage is out of the normal range (0.5 to 4.5 V), the pump controller recognizes the
relief pressure to be 0 MPa {0 kg/cm2}. Accordingly, perform troubleshooting, referring to Troubleshooting
(Failure code "DHPAMA and DHPBMA).
30-148 PC360LC-10
Electrical system
Adjustment (Cal R pump swash plate

sensor) (PC300-C3WB-273-K-00-A)
1. Preparation for calibration
under the following condition
• Hydraulic oil temperature: 50 °C
• Working mode: power Mode (P)
2. Selecting menu
screen.

select "Cal R pump swash plate sensor" by
using the function switches or numeral input
switches.
a Select this sub menu as in the case of
selecting a menu on the "Service Menu"
screen.
4. Perform the subsequent calibration procedure

according to "Adjustment (Cal F pump swash
plate sensor)".
However, when calibrating the R pump swash
plate, run the right track idle off ground by
operating the right travel lever to its stroke end.
PC360LC-10 30-149
Electrical system
Adjustment (Pump calibration: Matching speed check) (PC300-C200-280-K-00-A)

machine monitor.
The pump calibration function allows checking the
matching speed when the arm IN circuit or bucket
CURL circuit is relieved, and also allows setting an
appropriate matching speed with the engine when
the pump or pump controller is replaced.
a The pump calibration (calibration of matching
speed) is required in the following cases.
Pump
calibration
Replacement of engine ―
Replacement of main pump
Necessary
assembly
Replacement of pump controller Necessary
Adjustment and disassembly of
Necessary
front pump PC valve
Adjustment and disassembly of
Necessary
rear pump PC valve
Replacement of main valve ―
When main relief valve is adjusted
―
or replaced

a The following shows the outline of flow of
calibration of the pump.
• Implement warm-up operation for 30 minutes
In adjustment menu of service menu or more.
• Hydraulic oil temperature: 50 °C
• Air conditioner: OFF
screen.

After the "Adjustment" screen is displayed, input
"40" using the numeral input switches and press
"F6".
30-150 PC360LC-10
Electrical system
a This function is not added to the menu list

since it is required only when replacing a
pump, adjusting or disassembling a PC valve,
or replacing a pump controller.
2) In the following conditions, operate the arm

or bucket lever to check the relief matching.
(Operation)
Operate the arm or bucket lever according to
the instructions on the arm IN circuit or
4. Selection of the matching speed check menu
bucket CURL circuit relief screen.
After the "Pump calibration" screen is displayed,
select "Check matching speed" using the a Set the bucket CURL circuit relief
function switches or numeral input switches. matching after you have set the arm IN
circuit relief matching.
a Select it when you need to check the
machine for any trouble or its current state. Arm lever: Set the arm IN to full stroke
(do this setting when you perform the arm
The selection method is the same as that of
IN circuit relief matching)
the "Service Menu" screen.
Bucket lever: Set the bucket CURL to full
stroke (do this setting when you perform
the bucket CURL circuit relief matching)
(Conditions)
kA sufficient space must be secured

since you need to operate the work
equipment during the check.
[Reference]
k Pay attention to safety of the
• Alphabets in the upper right corner of the
screen represent the following situations. environment when operating the work
D: Default equipment.
F: Factory default (the setting done when
shipped from the plant (normal))
U: User's calibration value
5. Check of matching speed (relief of arm IN
circuit)
1) When the "Matching speed check" screen is
displayed, relieve the arm IN circuit and
check the matching speed using the function
switch.
[F1]: START
[F5]: Returns the display to the pump
calibration screen.
PC360LC-10 30-151
Electrical system
3) Relieve the arm IN circuit and, after the 6. Check of matching speed (relief of bucket CURL
engine speed stabilized, hold down [F1] on circuit relieved)
the machine monitor to start the check. 1) When the "Matching speed check" screen is
Since the screen displays a bar on it as long displayed, relieve the bucket CURL circuit
as the check of the matching speed is and check the matching speed using the
continued, maintain the relief operation until function switch.
the check is over. [F1]: START
• It takes 10 seconds for the bar graph to [F5]: Returns the display to the arm IN circuit
start moving. relief screen
4) As the correction is normally completed, the 2) Wait under the following conditions.
result is displayed. • Hydraulic oil temperature: 50 °C
Press [F6] to proceed to relief of the bucket • Working mode: P mode
CURL circuit. • Fuel control dial: Max.
3) Hold down [F1] of the machine monitor to
start the check.
Since the screen displays a bar on it as long
as the check of the matching speed is
continued, maintain the relief operation until
the check is over.
When the check ended abnormally, "NG" is

indicated on the screen along with the failure
cause code. So, reference the failure cause
code on Table 2 to identify the cause and
retry the matching speed check again.
4) As the correction is normally completed, the

result is displayed.
Press [F6] to return to the "Pump calibration"
screen.
30-152 PC360LC-10
Electrical system
When the check ended abnormally, "NG" is

indicated on the screen along with the failure
cause code. So, reference the failure cause
code on Table 1 to identify the cause and
retry the matching speed check again.
PC360LC-10 30-153
Electrical system
Table 1. Failure cause codes

Calibration failure cause codes (Displayed in descending order of priority)
Object
MIN MAX
code
plate plate
A-1 q q q Engine speed signal is 0 rpm Check that engine is started
Hydraulic oil temperature is Check hydraulic oil
A-2 q q q temperature (Min. 45 °C)
low
Check hydraulic oil
Hydraulic oil temperature is temperature (Calibration of
A-3 q q q high swash plate: Max. 85°C,
Pump calibration: Max. 55°C)
A-4 q q q Engine overheats Check for overheat
Pump pressure sensor (F, R) Perform troubleshooting for
A-6 q q q pump pressure sensor
is defective
Pump swash plate (F, R) Perform troubleshooting for
A-7 q q —
sensor is defective pump swash plate sensor
Arm IN PPC pressure sensor Perform troubleshooting of
A-8 — — q
is defective arm IN PPC pressure sensor
— — PC-EPC abnormality Perform troubleshooting of
A-9 q
PC-EPC
Defective CAN communication Perform troubleshooting of
A-A — — q (Eng, Monitor, Pump) CAN
— — Bucket CURL PPC pressure
A-B q bucket CURL PPC pressure
sensor is defective
sensor
B-1 q — —
pump is above standard value relief valve and pump
Set all control levers to
B-3 q q — Lever is not in NEUTRAL NEUTRAL position.
C-1 — q —
pump is below standard value relief valve and pump
— — Travel speed setting is not Hi Set travel speed switch to Hi
C-2 q
from the monitor.
Fuel control dial is not set to Set fuel control dial to Max.
C-3 — q q Max. position position.
Set travel lever to full stroke
C-4 — q — Both tracks are running and work equipment lever to
neutral.
Check the service flow rate
Oil flow from 2 pumps are not (Normally oil from the pump is
C-5 — q —
divided diverted when the travel circuit
is relieved singly)
Travel PPC pressure sensor is Perform troubleshooting of
C-6 — q —
defective travel PPC pressure sensor
— — Travel PPC pressure is below
C-7 q Set travel lever to full stroke.
standard value
Arm IN when the arm IN circuit
relieved
PPC pressure is below the
E-1 — — q Set arm lever to full stroke.
specified level or arm IN
PPC pressure sensor is out of
the normal range
Pump pressure (F, R) is out of Perform troubleshooting of
E-2 — — q the specified range relief valve and pump
30-154 PC360LC-10
Electrical system
Object
MIN MAX
code
plate plate
Engine speed is out of the Set the engine to Hi idle
E-3 — — q specified range speed.
Engine torque is out of the Perform troubleshooting of
E-4 — — q specified range engine and pump
PC-EPC current is out of the Perform troubleshooting of
E-5 — — q specified range PC-EPC current
When bucket CURL circuit is
relieved, bucket CURL PPC
pressure is below the
E-6 — — q Set bucket lever to full stroke.
specified value or bucket
CURL PPC pressure sensor is
out of the normal range.
Working mode is not set to [P] Set working mode is to [P] or
E-7 — — q or [ATT/P] [ATT/P].
Swing emergency stop switch Set swing emergency stop
E-8 — — q is not set to ON position switch to ON position.
Swing lock switch is not set to Set swing lock switch to ON
E-9 — — q ON position position.
Air conditioner is set to ON Set air conditioner to OFF
E-A — — q position position.
Output voltage of pump swash
FF q q — plate sensor is out of
swash plate sensor
calibration range
KDPF regeneration is
G-1 — — q End KDPF regeneration.
underway
(*1) When the sensor voltage is out of the normal range (0.5 to 4.5 V), the pump controller recognizes the
relief pressure to be 0 MPa {0 kg/cm2}. Accordingly, perform troubleshooting, referring to Troubleshooting
(Failure code "DHPAMA and DHPBMA).
PC360LC-10 30-155
Electrical system
Adjustment (Pump calibration: Matching

speed calibration) (PC220-C200-270-K-00-A)
under the following condition
• Perform warm-up operation for at least 30
minutes
• Fuel control dial: MAX position
2. Selecting menu
Select "Adjustment" on "Service Menu" screen. 5. Perform the subsequent calibration procedure
according to "Matching Speed Calibration".
No Injection (PC220-AD00-25L-K-00-A)
If the engine is operated after long storage of the
machine, it may be worn or damaged because of
insufficient lubrication with oil. To prevent this, the
machine monitor has a function to crank the engine
without injecting fuel to lubricate the engine before
starting it.
Set the No Injection cranking while the engine is
stopped.
1. Selecting menu
Select "No Injection" on "Service Menu" screen.
After the "Adjustment" screen is displayed, input
"40" by using the numeral input switches and
press "F6".
a Since this function is required only when the
pump is replaced, the PC valve is adjusted or
disassembled, or the pump controller is
replaced, it is not displayed in the menu list.
2. Displaying confirmation screen

When the "No Injection" screen is displayed, the
message to ask if no injection cranking should
be performed appears. Select the answer by
using the function switch.
• [F5]: Do not perform (return to Service Menu
screen)
• [F6]: Executes
4. Selecting matching speed calibration menu
After the "Pump Calibration" screen is displayed,
select "Matching Speed Calibration" by using
the function switch or numeral input switches.
30-156 PC360LC-10
Electrical system
a This function can be selected even when the

engine is running. However, if you execute
the no injection cranking, a message "The
engine is operating. Please turn the key off
once." is displayed on the screen.
3. Starting no injection cranking

If no injection cranking (no fuel injection to every
cylinder) is enabled, a message to notify that is
displayed on the screen. Under this condition,
crank the engine with the starting motor.
a While the screen is changing to the following Also, if the no injection cranking is operated
screen, the screen of "Getting Ready." is when Check screen is displayed, the function
displayed. does not become effective in the following
a Do not crank the engine for 20 seconds or case.
longer to protect the starting motor. • The communication between the monitor
and engine controller is not normal.
• Perform an engine start operation before
the message "No injection is possible" is
displayed.
4. Finishing no injection cranking

After the cranking is over, turn the starting switch
to OFF position.
a You cannot change the screen described
above to another screen. KOMTRAX Settings (Terminal Status) (PC220-
5. Prohibiting no injection cranking Q210-110-K-00-A)
Even if the operator tries to perform the no The setting and operating status of KOMTRAX can
injection cranking while the engine is running, be checked by using the menu of "KOMTRAX
the message "The engine is operating" is Settings".
displayed and the no injection cranking does not "KOMTRAX Settings" is used to check the setting
become effective. condition of the KOMTRAX terminal.
Select "KOMTRAX Settings" on the "Service
Menu" screen.
PC360LC-10 30-157
Electrical system
KOMTRAX Settings (GPS and Communication

Status) (PC220-Q210-110-K-01-A)
The setting and operating status of KOMTRAX can
be checked by using the menu of "KOMTRAX
Settings".
"GPS & Communication Status" is used to check
the positioning and communication status of the
KOMTRAX terminal.
Select "KOMTRAX Settings" on the "Service
Menu" screen.
2. Selecting submenu
After the “KOMTRAX Settings” screen is
displayed, select “Terminal Status” with the
function switches or numeral input switches.
a Select this submenu as in the case of
screen.

After the "KOMTRAX Settings" screen is
displayed, select "GPS & Communication
Status" with the function switches or numeral
input switches.
a Select this sub menu as in the case of
screen.
3. Contents displayed on the terminal status
screen
On the "Terminal Status" screen, the following
information is displayed.
• Terminal Type: Model name of the
KOMTRAX communication modem
• KOMTRAX Communication: Status of sign-
up test underway
• GMT time: Greenwich Mean Time (add 9
hours to it for Japan time)
• [F5]: Returns the display to the KOMTRAX
settings screen
3. Contents displayed on GPS & Communication

Status screen
On the "GPS & Communication Status" screen,
the following items are displayed.
• Positioning: GPS positioning status
• Communication: Communication
environment and connection status of the
communication modem
• Number of message not yet sent: Number of
mails that are saved on the machine monitor
and have not yet been transmitted
30-158 PC360LC-10
Electrical system
• [F5]: Returns the display to the KOMTRAX

settings screen
3. Details displayed on Modem Status screen

IP addresses (2 systems) of the modem are
displayed.
KOMTRAX Settings screen (Modem • [F5]: Returns the display to KOMTRAX
Status) (PC220-Q210-110-K-02-A) settings screen
The setting and operating conditions of KOMTRAX
a An IP address is a unique number assigned
can be checked through the display of KOMTRAX
to each modem that is used when
Settings.
communication between the modem and
Modem information is used to check the IP address server is established.
of the KOMTRAX communication modem.
1. Selection of menu
Select "KOMTRAX Settings" on "Service Menu"
screen.
Service Message (PC220-Q210-100-K-00-A)

Special messages for the technician sent from the
KOMTRAX base station (a distributor, etc.) can be
2. Selecting sub menu checked with this function.
After the "KOMTRAX Settings" screen is If a received message includes a setting operation,
displayed, select "Modem Status" by using the a return mail can be sent by using the numeral input
function switch or numeral input switches. switches as well.
a Select this item similarly to an item on the 1. Selecting menu
"Service Menu" screen. Select "Service Message" on "Service Menu"
screen.
PC360LC-10 30-159
Electrical system
a Since this message is special for the

technician, the message monitor is not
displayed when it is received with the
machine monitor in the operator mode.
2. Displaying message (read only)

If there is a message, its contents are displayed.
If there is no message, "No message." is
displayed.
• [F5]: Returns the display to Service Menu
screen
a This message is different from that sent to
the operator with the machine monitor in the
operator mode.
a Since this message is special for the
technician, the message monitor is not
displayed when it is received with the
machine monitor in the operator mode.
3. Display of message (with return mail function)

If a message provides the Numeric Input line
under the text, input a proper number by using
the numeral input switches and enter it by using
the function switch, and the information is
returned to the KOMTRAX base station.
• [F5]: Returns the display to KOMTRAX
settings screen
• [F6]: Enters and returns input value
a This message is different from that sent to
the operator with the machine monitor in the
operator mode.
30-160 PC360LC-10
Electrical system
Adjusting rearview camera angle (PC300-Q162-001-K-00-A)
a Adjust the camera so that persons in area (w) at a The claw of cover (2) is made of plastic, so
1 meter around the machine is displayed on the be careful not to break it when removing.
machine monitor in the operator cab.
a Prepare a work stand and reserve a safe place
to adjust the rear view camera. If you work
standing on the counterweight, you may fall and
may be injured seriously.
2. Remove bolts (3) from 2 places.

3. Remove cover (1).
a Check where and how many shims (6) have
been used.
Shims (6) are put on cover (1). Be careful not
If the image displayed on the monitor is out of to drop them.
position, remove cover (1) of the camera and adjust
the installation angle (A) of the rear view camera.
• Angle (A): 32 to 53 deg.
Adjusting (PC220-Q162-270-K-01-A)
1. Remove cover (1) by inserting flat-head

screwdriver [1] in the hole in cover (2) and
pressing the internal claw.
4. Loosen camera mounting bolts (4) (at 3 places)

and adjust camera mounting angle (A) so that
corner (B) of mounting bracket (5) is aligned with
horizontal line (C) of the camera.
PC360LC-10 30-161
Electrical system
a Using shims (6), adjust the difference

between the upper and lower clearances
between the counterweight and cover (1) to 2
mm or less.
a Since shim (6) may be caught in cover (1),

insert it from outside to the cover after
inserting the bolt temporarily.
a Machine is displayed partially on the

machine monitor screen.
5. After adjusting, tighten bolts (4).

3 Camera mounting bolt:
11.8 to 14.7 Nm {1.2 to 1.5 kgm}
6. Install covers (1) and (2).
30-162 PC360LC-10
Electrical system
Handling voltage circuit of engine controller (PC220-AP40-2A4-K-00-A)
1. Disconnecting or connecting work of the

connector between the engine controller and the
engine must be performed only when the
starting switch and disconnect switch are in OFF
position and the system operating lamp goes
out.
k Before connecting the wiring harness

connector, be sure to completely remove
sand, dust, water, etc., inside the
connector on the controller side.
2. If the T-adapter is inserted in or connected to the
connector between the engine controller and
engine harness for troubleshooting, do not start
the engine.
a You may turn the starting switch to OFF or
ON position but must not turn it to START
position.
PC360LC-10 30-163
Electrical system
Handling battery disconnect switch (PC400-AW1P-100-K-00-A)
1. Pull out switch key (1) whenever you have

turned the battery disconnect switch OFF.
kA serious accident can result if someone

turns switch key (1) ON inadvertently.
2. Check the operating condition of each controller
with system operating lamp (2) to prevent
abnormal stop by cutting out the battery power
supply circuit while the controllers are in
operation.
1) When cutting out the battery power supply
circuit, turn the starting switch to OFF
position and check that the system operating
lamp has gone out, and then turn the battery
disconnect switch to OFF position.
2) If the battery disconnect switch is turned to
OFF position (to cut out the battery power
supply circuit) while the system operating
lamp is lighting up, the data loss error may
occur in the controllers. Do not operate the
battery disconnect switch while the system
operating lamp is lighting up.
3) The system operating lamp goes out within 2
minutes after the starting switch is turned to
OFF position.
4) Even if the starting switch is in OFF position,
the system operating lamp may light up since
the KOMTRAX terminal may perform
communication.
5) Even if the system operating lamp is off, it
may seem to be lighting slightly because of a
very little current inside the controller. This
phenomenon does not indicate abnormality.
• The KOMTRAX terminal performs
communication periodically even if the
starting switch is kept in OFF position,
thus it starts and stops repeatedly.
• The starting and stopping period (sleep
cycle) of the KOMTRAX terminal varies
with the communication condition,
operation stop time, etc., and the terminal
may keep lighting up for a maximum of
approximately 1 hour.
6) To cut out the battery circuit for maintenance
while the system operating lamp is lighting
up, turn the starting switch to ON position
and then return to OFF position, and the
lamp goes out within 2 minutes.
After the system operating lamp goes out,
turn the battery disconnect switch to OFF
position immediately.
30-164 PC360LC-10
Electrical system
Testing diodes (ALL-E300-001-P-00-A)
a Test the diode array (8-pin) and the single diode

(2-pin) according to the following procedure.
a The continuity directions of the diode array are
as follows.
2. When using analog tester

1) Selects the resistance range screen.
2) Check the movement of the pointer when
performing the following connection.
1] Apply the red (+) lead of the multimeter to
a The continuity direction of the single diode is the anode (P) side of the diode and apply
indicated on the surface of the diode. the black (-) lead to the cathode (N) side.
Testing (PC220-E300-36J-P-00-A) 2] Apply the red (+) lead of the multimeter to
the cathode (N) side of the diode and
1. When using a digital tester apply the black (-) lead to the anode (P)
1) Select the diode range screen to check the side.
displayed values. 3) Evaluate the condition of the diode by the
a When an ordinary circuit tester is used, movement of the pointer.
the voltage of the internal battery is • The pointer does not move by the above
indicated. 1] connection, but it does by the 2]
2) Apply the red (+) lead of the multimeter to the connection: Normal (however, the
anode (P) side of the diode and apply the movement of the pointer (resistance)
black (-) lead to the cathode (N) side and varies by type of tester, or selection of
check the indicated value. measuring range).
3) Evaluate the condition of the diode by the • The pointer moves by either connection
indicated value. of the above 1], and 2]:
• Indicated value does not change: No Defective (internal short circuit)
continuity (defective) • The pointer moves by neither connection
• Indicated value changes: Continuity the above 1], nor 2]: Defective (internal
(normal) (note) open circuit)
Note: In the case of a silicon diode, a value in
the range from 460 to 600 mV is indicated.
• The indicated value is 0 or approximate
0:
The diode has internal short circuit
(defective).
PC360LC-10 30-165
Pm clinic
Pm clinic (ALL-2160-001-A-00-A)
Pm clinic service (PC300-2160-209-A-00-A)
Model Serial No. Service meter reading

T PC360LC-10 h
User name Date of inspection Inspector
/ /
Specifications
Main component Attachment Shoe width
Boom T Standard T ( ) T Breaker T 600 mm T( )
Arm T Standard T ( ) T( ) T 700 mm
Bucket T Standard T ( ) T( ) T 850 mm
Check of oil and coolant level
T Radiator coolant When necessary
T Engine oil T Damper case oil T Machinery case oil
T Hydraulic oil T Final drive case oil T( )
Ambient temperature Height above sea level
°C m
Operator's comment
Result of visual inspection
Mechanical system abnormality record Electrical system abnormality record

AA10NX ___times/ 1st at ___hrs. / last at ___hrs. ___times/ 1st at ___hrs. / last at ___hrs.
AB00KE ___times/ 1st at ___hrs. / last at ___hrs. ___times/ 1st at ___hrs. / last at ___hrs.
B@BAZG ___times/ 1st at ___hrs. / last at ___hrs. ___times/ 1st at ___hrs. / last at ___hrs.
B@BAZK ___times/ 1st at ___hrs. / last at ___hrs. ___times/ 1st at ___hrs. / last at ___hrs.
B@BCNS ___times/ 1st at ___hrs. / last at ___hrs. ___times/ 1st at ___hrs. / last at ___hrs.
B@BCZK ___times/ 1st at ___hrs. / last at ___hrs. ___times/ 1st at ___hrs. / last at ___hrs.
B@HANS ___times/ 1st at ___hrs. / last at ___hrs. ___times/ 1st at ___hrs. / last at ___hrs.
CA234 ___times/ 1st at ___hrs. / last at ___hrs. ___times/ 1st at ___hrs. / last at ___hrs.
30-166 PC360LC-10
Pm clinic
Max. range of engine coolant temperature gauge
Coolant temperature gauge level Engine coolant Temperature Color of monitor light (a)
6 105 °C
Red
5 102 °C
4 100 °C
3 85 °C Blue
2 60 °C
1 30 °C White
Max. range of hydraulic oil temperature gauge
Hydraulic oil temperature gauge Hydraulic oil temperature Color of monitor light (a)
level
6 105 °C
Red
5 102 °C
4 100 °C
3 85 °C Blue
2 40 °C
1 20 °C White
PC360LC-10 30-167
Pm clinic
Check items related to engine
30-168 PC360LC-10
Pm clinic
Check items related to hydraulic oil pressure
PC360LC-10 30-169
Pm clinic
Check sheet (PC300_10-2160-033-A-00-A)
Check sheet (PC360LC-10)

Service meter Date of
Model Serial No. User name Inspector
reading inspection
/ /
1. Engine
Measuring conditions
One-touch power
Standard
No good
max. switch
Fuel control
decelerator
Swing lock
equipment
Mea-
Operation
Good
Working
Measuring value for Repair limit
of work
switch
mode
Auto-
No. Unit sured

dial
item new
value
machine
Engine 2,020 to 2,020 to rpm

1 speed 2,080 2,080
All levers
MAX ON in 0.34 to
Engine oil MPa Min. 0.21
2 pressure NEUTRAL 0.59
{kg/cm2} {2.1}
OFF {3.5 to 6.0}
Engine rpm 975 to 975 to
3 speed All levers 1,025 1,025
MIN OFF *1 in
Engine oil MPa Min. 0.15 Min. 0.08
4 pressure P NEUTRAL
{kg/cm2} {1.5} {0.8}
Engine rpm 1,830 to 1,830 to
5 speed
2,030 2,030
Arm IN
OFF ON kPa
Blowby relief Max. 1.57 Max. 2.55
6 pressure {mm
MAX {160} {260}
H2O}
Engine All levers 970 to 970 to
7 speed ON *1 OFF in rpm
1,030 1,030
NEUTRAL
*1: ON or OFF
30-170 PC360LC-10
Pm clinic
2. Work equipment speed

Standard
No good
Fuel control
Mea-
Good
Working
value for
mode
No. Measuring item Measuring posture, Unit Repair limit sured
dial
new
etc. value
machine
Work equipment
1 Boom Raise extended fully 3.3 to 4.1 Max. 4.5
P
2 Arm OUT 2.6 to 3.2 Max. 3.5
Boom top face 3.5 to 4.3 Max. 4.5
3 Arm IN E horizontal 3.5 to 4.3 Max. 4.5
L 4.4 to 5.4 Max. 5.7
Boom top face
4 Bucket Curl MAX horizontal, arm sec. 2.9 to 3.5 Max. 3.8
cylinder retracted fully
Work equipment
5 Swing (5 turns) extended fully, swing 30.7 to 32.5 Max. 38
P
right and left
One track raised Li 46.5 to 69.5 45.0 to 74.5
Travel off ground and
6 Mi 35.5 to 47.5 34.0 to 51.5
(idle turns of track) run idle forward
and reverse Hi 32.0 to 36.0 32.0 to 41.5
3. Hydraulic drift of work equipment
Standard
No good
Fuel control
Mea-
Good
Working
value for
mode
No. Measuring item Measuring posture, Unit Repair limit sured

dial
new
etc. value
machine
Hydraulic drift Boom top face

measured at horizontal, arm
Engine cylinder retracted fully, mm/15
1 bucket tooth tip stop Max. 550 Max. 825
(entire work bucket cylinder min
equipment) extended fully, rated
load on bucket
PC360LC-10 30-171
Pm clinic
4. Hydraulic circuit
Measuring conditions [1] [2] [3] [4] [5]
60 MPa 60 MPa 60 MPa 60 MPa 6 MPa
No good
Fuel control
power max.
{600 kg/ {600 kg/ {600 kg/ {600 kg/ {60 kg/
One-touch
Good
Working
Testing
switch
mode
No. Operation of cm2} cm2} cm2} cm2} cm2}
tools dial
work equipment F pump R pump F pump R pump Control
delivery delivery LS LS circuit oil
pressure pressure pressure pressure pressure
Self- A
pressure All levers in ― ― ― ―
1
reducing NEUTRAL
valve OFF
Main relief B B
2 valve (low ― ― ―
pressure)
Arm IN relief
Main relief C C
3 valve (high ON ― ― ―
pressure)
Unload All levers in D D ― ― ―
4
valve NEUTRAL
Right track E1 E2
running Hi idle
off ground, ― ― ―
lever at half
stroke
5 LS valve
Left track E1 E2
running Hi idle
off ground, ― ― ―
lever at half
MAX P stroke
Swing locked, F F
Swing swing right ― ― ―
6 motor relief
safety valve Swing locked, F F
― ― ―
OFF swing left relief
Right Hi travel G
locked, right ― ― ― ―
travel forward
relief
Right Hi travel G
Main relief
locked, right ― ― ― ―
valve, travel
travel reverse
motor
relief
7 safety
Left Hi travel G
valve, travel
locked, left ― ― ― ―
junction
travel forward
valve
relief
Left Hi travel G
locked, left ― ― ― ―
travel reverse
relief
30-172 PC360LC-10
Pm clinic
Oil pressure to be measured Standard value for new Repair limit

Unit
machine
A (Control source pressure) 3.03 to 3.43 {31 to 35} 2.84 to 3.43 {29 to 35}
B (Work equipment relief pressure,
33.63 to 36.28 {343 to 370} 33.15 to 36.77 {338 to 375}
low)
Standard
value
C (Work equipment relief pressure,

MPa 36.08 to 38.73 {368 to 395} 35.6 to 39.23 {363 to 400}
high)
D (Unload pressure) {kg/cm2} 2.9 to 4.9 {30 to 50} 2.9 to 4.9 {30 to 50}
E (LS differential pressure) E1-E2 2.35 to 2.55 {24 to 26} 2.35 to 2.55 {24 to 26}
F (Swing relief pressure) 28.42 to 32.34 {290 to 335} 28.42 to 32.85 {285 to 335}
G (Travel relief pressure) 36.29 to 40.2 {370 to 410} 35.8 to 40.7 {365 to 415}
* Oil pressure gauge connection changing work: Exchange hoses of gauges [3] and [4].
Measuring conditions [1] [2] [3a] [4a] [5]
{600 kg/ {600 kg/ {600 kg/ {600 kg/ {60 kg/
No good
Fuel control
power max.
One-touch
cm2} cm2} cm2} cm2} cm2}
Good
Working
Measuring
switch
mode
No. Operation of F pump R pump

dial
tools
work equipment F pump R pump servo servo Control
delivery delivery piston piston circuit oil
pressure pressure inlet inlet pressure
pressure pressure
Arm IN relief H1 H1 H2 H2 ―
Right track H1 H2
running idle off ― ― ―
Servo ground, lever at
8 piston MAX P OFF half stroke
Left track H1 H2
running idle off ― ― ―
ground, lever at
half stroke
Standard value for new
Standard
Oil pressure to be measured Unit Repair limit

machine
value
H1: H2 = 1: 0.6
H (Servo control pressure) ―
(Oil pressure ratio)
* Oil pressure gauge connection changing work: Change gauges [3] and [4] to 6 MPa {60 kg/cm 2} and
exchange hoses of [3], [4], and [5] gauges.
Measuring conditions [1] [2] [3b] [4b] [5a]
{600 kg/ {600 kg/ {60 kg/ {60 kg/ {60 kg/
No good
Fuel control
power max.
cm2} cm2} cm2} cm2} cm2}

One-touch
Good
Working
Measuring
switch
mode
No. Operation of F pump R pump

dial
tools LS-EPC
work equipment F pump R pump PC-EPC PC-EPC valve
delivery delivery valve valve output
pressure pressure output output pressure
pressure pressure
PC-EPC (F) MIN ― ― J1 J1 ―
valve P
All levers in ― ― J2 J2 ―
9
PC-EPC (R) NEUTRAL J3 J3
E ― ― ―
valve
Travel speed: K1
OFF
MAX Lo, travel lever ― ― ― ―
LS-EPC fine operation
10 P
valve Travel speed: K2
HI, travel lever ― ― ― ―
fine operation
PC360LC-10 30-173
Pm clinic
Oil pressure to be measured Unit Reference values

J1 (PC-EPC valve output pressure 1) Approx. 1.74 {17.1}
Standard
value

MPa
{kg/cm2}
K1 (LS-EPC valve output pressure 1) Approx. 1.45 {14.8}
K2 (LS-EPC valve output pressure 2) 0 {0}
30-174 PC360LC-10
SHOP MANUAL
HYDRAULIC EXCAVATOR
PC360LC-10
Model Serial Number
PC360LC-10 70001 and up
40 Troubleshooting
6 40 Troubleshooting
PC360LC-10 40-1
40 Troubleshooting
Table of contents

40 Troubleshooting............................................................................................................................ 40-1
Related information on troubleshooting......................................................................................... 40-9
Troubleshooting points ......................................................................................................... 40-9
Sequence of events in troubleshooting................................................................................. 40-11
Checks before troubleshooting ............................................................................................ 40-13
Inspection procedure before troubleshooting ........................................................................ 40-15
Preparation work for troubleshooting of electrical system....................................................... 40-34
Classification and procedure for troubleshooting ................................................................... 40-41
Symptom and troubleshooting numbers ............................................................................... 40-44
Troubleshooting method for open circuit in wiring harness of pressure sensor system .............. 40-49
Connector list and layout .................................................................................................... 40-51
Connector contact identification........................................................................................... 40-62
T-branch box and T-branch adapter table ........................................................................... 40-100
Fuse location table ........................................................................................................... 40-105
Preparation of dummy temperature sensor (for KDOC and KDPF temperature
sensors)............................................................................................................. 40-107
Preparation of short circuit electrical connector (for failure codes [CA1883] and
[CA3135]) .......................................................................................................... 40-108
Precautions for KDPF (KCSF and KDOC) Cleaning and Replacement ................................. 40-109
Failure codes table........................................................................................................... 40-112
Troubleshooting by failure code (Display of code) ...................................................................... 40-121
Failure code [879AKA] A/C Inner Sensor Open Circuit ........................................................ 40-121
Failure code [879AKB] A/C Inner Sensor Short Circuit......................................................... 40-122
Failure code [879BKA] A/C Outer Sensor Open Circuit........................................................ 40-123
Failure code [879BKB] A/C Outer Sensor Short Circuit ........................................................ 40-124
Failure code [879CKA] Ventilating Sensor Open Circuit ....................................................... 40-125
Failure code [879CKB] Ventilating Sensor Short Circuit ....................................................... 40-126
Failure code [879DKZ] Sunlight Sensor Open Or Short Circuit ............................................. 40-127
Failure code [879EMC] Ventilation Damper Abnormality ...................................................... 40-128
Failure code [879FMC] Air Mix Damper Abnormality ........................................................... 40-129
Failure code [879GKX] Refrigerant Abnormality .................................................................. 40-130
Failure code [989L00] Engine Controller Lock Caution 1...................................................... 40-131
Failure code [989M00] Engine Controller Lock Caution 2..................................................... 40-132
Failure code [989N00] Engine Controller Lock Caution 3 ..................................................... 40-133
Failure code [AA10NX] Air Cleaner Clogging ...................................................................... 40-138
Failure code [AB00KE] Charge Voltage Low....................................................................... 40-140
Failure code [B@BAZG] Eng Oil Press Low ....................................................................... 40-142
Failure code [B@BAZK] Eng Oil Level Low ........................................................................ 40-143
Failure code [B@BCNS] Eng Water Overheat .................................................................... 40-144
Failure code [B@BCZK] Eng Water Level Low ................................................................... 40-145
Failure code [B@HANS] Hyd Oil Overheat ......................................................................... 40-147
Failure code [CA115] Eng Ne and Bkup Speed Sens Error .................................................. 40-148
Failure code [CA122] Chg Air Press Sensor High Error ....................................................... 40-149
Failure code [CA123] Chg Air Press Sensor Low Error ........................................................ 40-151
Failure code [CA131] Throttle Sensor High Error................................................................. 40-153
Failure code [CA132] Throttle Sensor Low Error ................................................................. 40-155
Failure code [CA144] Coolant Temp Sens High Error .......................................................... 40-157
Failure code [CA145] Coolant Temp Sens Low Error ........................................................... 40-159
Failure code [CA153] Chg Air Temp Sensor High Error ........................................................ 40-161
Failure code [CA154] Chg Air Temp Sensor Low Error......................................................... 40-163
Failure code [CA221] Ambient Press Sensor High Error ...................................................... 40-167
Failure code [CA222] Ambient Press Sensor Low Error ....................................................... 40-169
40-2 PC360LC-10
40 Troubleshooting
Table of contents

Failure code [CA234] Eng Overspeed ................................................................................ 40-172
Failure code [CA238] Ne Speed Sensor Supply Volt Error ................................................... 40-173
Failure code [CA239] Ne Speed Sens Supply Volt High Error............................................... 40-174
Failure code [CA271] IMV/PCV1 Short Error ...................................................................... 40-175
Failure code [CA272] IMV/PCV1 Open Error ...................................................................... 40-177
Failure code [CA281] Pump Press Balance Error ................................................................ 40-179
Failure code [CA295] Ambient Pressure Sensor In Range Error ........................................... 40-180
Failure code [CA343] ECM Critical Internal Failure.............................................................. 40-193
Failure code [CA351] Injectors Drive Circuit Error ............................................................... 40-194
Failure code [CA356] Mass Air Flow Sensor High Error ....................................................... 40-197
Failure code [CA357] Mass Air Flow Sensor Low Error ........................................................ 40-199
Failure code [CA428] Water in Fuel Sensor High Error ........................................................ 40-202
Failure code [CA429] Water in Fuel Sensor Low Error ......................................................... 40-204
Failure code [CA435] Eng Oil Press Sw Error ..................................................................... 40-206
Failure code [CA441] Battery Voltage Low Error ................................................................. 40-207
Failure code [CA442] Battery Voltage High Error................................................................. 40-209
Failure code [CA449] Rail Press Very High Error................................................................. 40-210
Failure code [CA451] Rail Press Sensor High Error............................................................. 40-212
Failure code [CA452] Rail Press Sensor Low Error ............................................................. 40-214
Failure code [CA488] Chg Air Temp High Torque Derate...................................................... 40-216
Failure code [CA515] Rail Press Sens Sup Volt High Error .................................................. 40-217
Failure code [CA516] Rail Press Sens Sup Volt Low Error ................................................... 40-219
Failure code [CA553] Rail Press High Error ........................................................................ 40-221
Failure code [CA559] Rail Pump Press Low Error ............................................................... 40-224
Failure code [CA595] Turbo Speed High Error 2 ................................................................. 40-228
Failure code [CA687] Turbo Speed Low Error ..................................................................... 40-229
Failure code [CA689] Eng Ne Speed Sensor Error .............................................................. 40-231
Failure code [CA691] Intake Air Temp Sens High Error ........................................................ 40-235
Failure code [CA692] Intake Air Temp Sens Low Error......................................................... 40-237
Failure code [CA697] ECM Internal Temp Sensor High Error................................................ 40-239
Failure code [CA698] ECM Int Temp Sensor Low Error........................................................ 40-240
Failure code [CA731] Eng Bkup Speed Sens Phase Error ................................................... 40-241
Failure code [CA778] Eng Bkup Speed Sensor Error........................................................... 40-243
Failure code [CA1117] Persistent Data Lost Error................................................................ 40-248
Failure code [CA1664] KDOC Malfunction.......................................................................... 40-249
Failure code [CA1691] Regeneration Ineffective ................................................................. 40-251
Failure code [CA1695] Sens 5 Supply Volt High Error.......................................................... 40-254
Failure code [CA1696] Sens 5 Supply Volt Low Error .......................................................... 40-255
Failure code [CA1843] Crankcase Press Sens High Error.................................................... 40-257
Failure code [CA1844] Crankcase Press Sens Low Error .................................................... 40-259
Failure code [CA1879] KDPF Delta P Sensor High Error ..................................................... 40-261
Failure code [CA1881] KDPF Delta P Sensor Low Error ...................................................... 40-263
Failure code [CA1883] KDPF Delta P Sens In Range Error.................................................. 40-265
Failure code [CA1942] Crankcase Press Sens In Range Error ............................................. 40-276
Failure code [CA1993] KDPF Delta Pressure Low Error ...................................................... 40-277
Failure code [CA2185] Throt Sens Sup Volt High Error ........................................................ 40-280
PC360LC-10 40-3
40 Troubleshooting
Table of contents
Failure code [CA2186] Throt Sens Sup Volt Low Error......................................................... 40-282
Failure code [CA2249] Rail Press Very Low Error ............................................................... 40-284
Failure code [CA2265] Fuel Feed Pump Open Error............................................................ 40-285
Failure code [CA2266] Fuel Feed Pump Short Error ............................................................ 40-287
Failure code [CA2271] EGR Valve Pos Sens High Error ...................................................... 40-289
Failure code [CA2272] EGR Valve Pos Sens Low Error ....................................................... 40-291
Failure code [CA2288] Turbo Speed High Error 1................................................................ 40-294
Failure code [CA2311] IMV Solenoid Error ......................................................................... 40-295
Failure code [CA2349] EGR Valve Solenoid Open Error ...................................................... 40-296
Failure code [CA2353] EGR Valve Solenoid Short Error ...................................................... 40-298
Failure code [CA2357] EGR Valve Servo Error ................................................................... 40-300
Failure code [CA2373] Exhaust Manifold Press Sens High error........................................... 40-301
Failure code [CA2374] Exhaust Manifold Press Sens Low error ........................................... 40-303
Failure code [CA2375] EGR Orifice Temp Sens High Error .................................................. 40-305
Failure code [CA2376] EGR Orifice Temp Sens Low Error ................................................... 40-307
Failure code [CA2381] KVGT Pos Sens High Error ............................................................. 40-309
Failure code [CA2382] KVGT Pos Sens Low Error .............................................................. 40-311
Failure code [CA2383] KVGT Solenoid Open Error ............................................................. 40-314
Failure code [CA2386] KVGT Solenoid Short Error ............................................................. 40-316
Failure code [CA2387] KVGT Servo Error .......................................................................... 40-318
Failure code [CA2554] Exh Manifold Press Sens In Range Error .......................................... 40-319
Failure code [CA2555] Grid Htr Relay Open Circuit Error ..................................................... 40-320
Failure code [CA2556] Grid Htr Relay Short Circuit Error ..................................................... 40-322
Failure code [CA2637] KDOC Face Plugging ..................................................................... 40-324
Failure code [CA2639] Manual Stationary Regeneration Request......................................... 40-326
Failure code [CA2961] EGR Orifice Temp High Error 1 ........................................................ 40-329
Failure code [CA2973] Chg Air Press Sensor In Range Error ............................................... 40-330
Failure code [CA3133] KDPF Outlet Press Sens High Error ................................................. 40-331
Failure code [CA3134] KDPF Outlet Press Sens Low Error.................................................. 40-333
Failure code [CA3135] KDPF Outlet Press Sens In Range Error .......................................... 40-335
Failure code [CA3251] KDOC Inlet Temp High Error............................................................ 40-339
Failure code [CA3253] KDOC Temp Error - Non Regeneration............................................. 40-342
Failure code [CA3254] KDOC Outlet Temp High Error 1 ...................................................... 40-345
Failure code [CA3255] KDPF Temp Error - Non Regeneration.............................................. 40-348
Failure code [CA3311] KDOC Outlet Temp High Error 2....................................................... 40-354
Failure code [CA3313] KDOC Inlet Temp Sensor Low Error ................................................. 40-360
Failure code [CA3314] KDOC Inlet Temp Sens High Error ................................................... 40-363
Failure code [CA3315] KDOC Inlet Temp Sens In Range Error............................................. 40-367
Failure code [CA3316] KDOC Outlet Temp Sens Low Error ................................................. 40-371
Failure code [CA3317] KDOC Outlet Temp Sens High Error................................................. 40-374
Failure code [CA3318] KDOC Outlet Temp Sens In Range Error .......................................... 40-378
Failure code [CA3319] KDPF Outlet Temp Sens High Error ................................................. 40-382
Failure code [CA3321] KDPF Outlet Temp Sens Low Error .................................................. 40-386
Failure code [CA3322] KDPF Outlet Temp Sens In Range Error........................................... 40-389
Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error ........................................ 40-393
Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error ......................................... 40-395
Failure code [CA3741] Rail Press Valve Trip Error............................................................... 40-397
Failure code [D110KB] Battery Relay Drive S/C .................................................................. 40-398
Failure code [D19JKZ] Personal Code Relay Abnormality.................................................... 40-400
Failure code [D811MC] KOMTRAX Error............................................................................ 40-403
Failure code [D862KA] GPS Antenna Open Circuit ............................................................. 40-404
Failure code [D8ALKA] System Operating Lamp Disconnection (KOMTRAX)........................ 40-405
Failure code [D8ALKB] System Operating Lamp Short Circuit (KOMTRAX) .......................... 40-407
Failure code [D8AQKR] CAN2 Discon (KOMTRAX) ............................................................ 40-408
Failure code [DA20MC] Pump Controller Malfunction .......................................................... 40-409
Failure code [DA22KK] Pump Solenoid Power Low Error..................................................... 40-410
Failure code [DA25KP] 5V Sensor1 Power Abnormality ...................................................... 40-412
40-4 PC360LC-10
40 Troubleshooting
Table of contents
Failure code [DA29KQ] Model Selection Abnormality .......................................................... 40-415

Failure code [DA2LKA] System Operating Lamp Disconnection (Pump Con) ........................ 40-417
Failure code [DA2LKB] System Operating Lamp Short Circuit (Pump Con) ........................... 40-419
Failure code [DA2QKR] CAN2 Discon ( Pump Con) ............................................................ 40-420
Failure code [DA2RKR] CAN1 Discon ( Pump Con) ............................................................ 40-423
Failure code [DAF0MB] Monitor ROM Abnormality.............................................................. 40-424
Failure code [DAF0MC] Monitor Error ................................................................................ 40-425
Failure code [DAF8KB] Camera Power Supply Short Circuit ................................................ 40-426
Failure code [DAF9KQ] Model Selection Abnormality .......................................................... 40-428
Failure code [DAFGMC] GPS Module Error........................................................................ 40-429
Failure code [DAFLKA] Operating Lamp Open Circuit(Monitor) ............................................ 40-430
Failure code [DAFLKB] System Operating Lamp Short Circuit (Monitor)................................ 40-432
Failure code [DAFQKR] CAN2 Discon (Monitor) ................................................................. 40-433
Failure code [DAZ9KQ] AC Model Selection Abnormality .................................................... 40-434
Failure code [DAZQKR] CAN2 Discon (AC)........................................................................ 40-435
Failure code [DB2QKR] CAN2 Discon (Engine Con) ........................................................... 40-440
Failure code [DB2RKR] CAN1 Discon (Engine Con) ........................................................... 40-445
Failure code [DGH2KB] Hyd Oil Sensor Short Circuit .......................................................... 40-449
Failure code [DHA4KA] Air Cleaner Clogging Sensor Open Circuit ....................................... 40-451
Failure code [DHPAMA] Pump Press Sensor Abnormality ................................................... 40-453
Failure code [DHPBMA] R Pump Press Sensor Abnormality ................................................ 40-456
Failure code [DHS3MA] Arm IN PPC Sen. Abnormality ....................................................... 40-459
Failure code [DHS4MA] Bucket CURL PPC Press Sensor Abnormality ................................ 40-461
Failure code [DHS8MA] Boom RAISE PPC Press Sensor Abnormality ................................. 40-464
Failure code [DHS9MA] Boom LOWER Press Sensor Abnormality....................................... 40-467
Failure code [DHSAMA] Swing RH PPC Press Sensor Abnomality....................................... 40-470
Failure code [DHSBMA] Swing LH PPC Press Sensor Abnomality ....................................... 40-473
Failure code [DHSCMA] Arm OUT PPC Press Sensor Abnormality ...................................... 40-476
Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality ................................ 40-479
Failure code [DHSFMA] Travel FW L PPC Press Sensor Abnormality................................... 40-482
Failure code [DHSGMA] Travel FW R PPC Press Sensor Abnormality ................................. 40-485
Failure code [DHSHMA] Travel BW L PPC Press Sensor Abnormality .................................. 40-488
Failure code [DHSJMA] Travel BW R PPC Press Sensor Abnormality .................................. 40-491
Failure code [DKR0MA] F pump S/P sensor Abnormality..................................................... 40-494
Failure code [DKR1MA] R pump S/P sensor Abnormality .................................................... 40-496
Failure code [DV20KB] Travel Alarm Short Circuit............................................................... 40-502
Failure code [DW43KA] Travel Speed Sol Open Circuit ....................................................... 40-504
Failure code [DW43KB] Travel Speed Sol Short Circuit ....................................................... 40-506
Failure code [DW45KA] swing holding brake Sol Open Circuit ............................................. 40-508
Failure code [DW45KB] Swing Brake Sol Short Circuit ........................................................ 40-511
Failure code [DW91KA] Travel Junction Sol Open Circuit .................................................... 40-514
Failure code [DW91KB] Travel Junction Sol Short Circuit..................................................... 40-516
Failure code [DWA2KA] Attachment Sol Open Circuit.......................................................... 40-518
Failure code [DWA2KB] Attachment Sol Short Circuit.......................................................... 40-520
Failure code [DWK0KA] 2-stage Relief Sol Open Circuit ...................................................... 40-522
Failure code [DWK0KB] 2-stage Relief Sol Short Circuit ...................................................... 40-524
Failure code [DWK2KA] Variable Back Pressure Sol Open Circuit ........................................ 40-526
Failure code [DWK2KB] Variable Back Pressure Sol Short Circuit ........................................ 40-528
Failure code [DWK8KA] Swing C/O Solenoid Open Circuit .................................................. 40-530
Failure code [DWK8KB] Swing C/O Solenoid Short Circuit................................................... 40-532
Failure code [DXA8KA] PC-EPC (F) Sol Open Circuit.......................................................... 40-534
Failure code [DXA8KB] PC-EPC (F) Sol Short Circuit.......................................................... 40-536
Failure code [DXA9KA] PC-EPC (R) Sol Open Circuit ......................................................... 40-538
Failure code [DXA9KB] PC-EPC (R) Sol Short Circuit ......................................................... 40-540
Failure code [DXE0KA] LS-EPC Sol Open Circuit ............................................................... 40-542
Failure code [DXE0KB] LS-EPC Sol Short Circuit ............................................................... 40-544
Failure code [DXE4KA] Service Current EPC Disc. ............................................................. 40-546
PC360LC-10 40-5
40 Troubleshooting
Table of contents
Failure code [DXE4KB] Service Current EPC S/C ............................................................... 40-547

Failure code [DXE5KA] Merge-divider Main Sol Open Circuit ............................................... 40-548
Failure code [DXE5KB] Merge-divider Main Sol Short Circuit ............................................... 40-550
Failure code [DXE6KA] Merge-divider LS Sol Open Circuit .................................................. 40-552
Failure code [DXE6KB] Merge-divider LS Sol Short Circuit .................................................. 40-554
Failure code [DY20KA] Wiper Working Abnormality ............................................................ 40-556
Failure code [DY20MA] Wiper Parking Abnormality............................................................. 40-558
Failure code [DY2CKB] Washer Drive Short Circuit ............................................................. 40-560
Failure code [DY2DKB] Wiper Drive (For) Short .................................................................. 40-562
Failure code [DY2EKB] Wiper Drive (Rev) Short ................................................................. 40-564
Troubleshooting of electrical system (E-mode) .......................................................................... 40-566
E-1 Engine does not start (Engine does not crank) .............................................................. 40-566
E-2 Manual preheating does not work ................................................................................ 40-572
E-3 Automatic preheating system does not work................................................................. 40-575
E-4 While preheating is working, preheating monitor does not light up .................................. 40-577
E-5 When starting switch is turned to ON position, machine monitor displays nothing............. 40-579
E-6 While starting switch is turned to ON position (with engine stopped), engine oil level
E-7 While starting switch is turned to ON position (with engine stopped), radiator coolant level
E-8 Engine coolant temperature monitor lights up in white while engine is running ................. 40-584
E-9 Hydraulic oil temperature monitor lights up in white while engine is running ..................... 40-585
E-10 Charge level monitor lights up in red while engine is running ........................................ 40-586
E-11 Fuel level monitor lights up in red while engine is running............................................. 40-587
E-12 Air cleaner clogging monitor lights up in yellow while engine is running ......................... 40-588
E-13 Engine coolant temperature monitor lights up in red while engine is running .................. 40-589
E-14 Hydraulic oil temperature monitor lights up in red while engine is running ...................... 40-590
E-15 Engine oil pressure monitor lights up in red while engine is running .............................. 40-591
E-16 Fuel gauge display does not move from minimum or maximum .................................... 40-592
E-17 Display of fuel gauge differs from actual fuel level ....................................................... 40-593
E-18 Engine coolant temperature gauge display does not move from minimum or
maximum ........................................................................................................... 40-594
E-19 Display of engine coolant temperature gauge differs from actual coolant
temperature ....................................................................................................... 40-595
E-20 Hydraulic oil temperature gauge display does not move from minimum or
maximum ........................................................................................................... 40-596
E-21 Display of hydraulic oil temperature gauge differs from actual oil temperature ................ 40-598
E-22 Machine monitor does not display partially.................................................................. 40-599
E-23 Function switch does not operate............................................................................... 40-600
E-24 Automatic warm-up system does not work (in cold weather)......................................... 40-601
E-25 When auto-decelerator switch is operated, auto-decelerator monitor does not light up or
does not go off.................................................................................................... 40-602
E-26 Auto-decelerator is not operated or canceled with lever ............................................... 40-603
E-27 When working mode switch is operated, working mode selection screen is not
displayed ........................................................................................................... 40-604
E-28 When working mode is changed, setting of engine and hydraulic pump is not
changed............................................................................................................. 40-605
E-29 When travel speed switch is operated, travel speed monitor does not change ............... 40-606
E-30 When travel speed selection is changed, actual travel speed does not change .............. 40-607
E-31 Alarm buzzer cannot be canceled .............................................................................. 40-608
E-32 When starting switch is turned OFF, service meter is not displayed ............................... 40-609
E-33 Machine monitor cannot be set in service mode .......................................................... 40-610
E-34 Any of work equipment, swing and travel does not work............................................... 40-611
E-35 Any of work equipment, swing and travel cannot be locked .......................................... 40-613
E-36 Upper structure does not swing while swing brake cancel switch is set to CANCEL
position .............................................................................................................. 40-615
E-37 Swing brake does not operate while swing brake cancel switch is set to NORMAL
position .............................................................................................................. 40-617
40-6 PC360LC-10
40 Troubleshooting
Table of contents
E-38 One-touch power maximizing function does not work properly or pilot monitor is not
displayed ........................................................................................................... 40-619
E-39 One-touch power maximizing function cannot be canceled .......................................... 40-621
E-40 Alarm does not sound during travel ............................................................................ 40-622
E-41 Alarm does not stop sounding while machine is stopped.............................................. 40-624
E-42 Horn does not sound ................................................................................................ 40-625
E-43 Horn does not stop sounding..................................................................................... 40-627
E-44 When wiper switch is operated, wiper monitor does not light up or go off ....................... 40-628
E-45 Wiper does not operate when wiper switch is operated ................................................ 40-629
E-46 When window washer switch is operated, window washer does not operate.................. 40-631
E-47 Boom LOWER indicator is not displayed properly with monitoring function .................... 40-632
E-48 Arm OUT indicator is not displayed properly with monitoring function ............................ 40-633
E-49 Arm IN indicator is not displayed properly with monitoring function................................ 40-634
E-50 Boom RAISE indicator is not displayed properly with monitoring function ...................... 40-635
E-51 Bucket CURL indicator is not displayed properly with monitoring function...................... 40-636
E-52 Bucket DUMP indicator is not displayed properly with monitoring function ..................... 40-637
E-53 Swing indication is not displayed properly with monitoring function ............................... 40-638
E-54 Travel indication is not displayed properly with monitoring function ............................... 40-639
E-55 Service indication is not displayed properly with monitoring function ............................. 40-640
E-56 Attachment circuit is not switched .............................................................................. 40-642
E-57 KOMTRAX system does not operate properly............................................................. 40-643
E-58 Machine push-up function is not canceled .................................................................. 40-644
E-59 Machine push-up function does not work.................................................................... 40-646
Troubleshooting of hydraulic and mechanical system (H-mode) .................................................. 40-647
Information described in troubleshooting table (H-mode) ..................................................... 40-647
List of Failure Mode and Cause ......................................................................................... 40-648
H-1 All of work equipment, swing and travel operation lacks speed or power ......................... 40-653
H-2 Engine speed lowers significantly or engine stalls ......................................................... 40-657
H-3 Any of work equipment, swing and travel does not work ................................................ 40-660
H-4 Unusual sound is heard from around hydraulic pump .................................................... 40-661
H-5 Fine control performance or response is poor　............................................................ 40-662
H-6 Speed or power of boom is low.................................................................................... 40-664
H-7 Speed or power of arm is low ...................................................................................... 40-668
H-8 Speed or power of bucket is low .................................................................................. 40-673
H-9 Work equipment does not move in single operation....................................................... 40-677
H-10 Hydraulic drift of boom is large .................................................................................. 40-678
H-11 Hydraulic drift of arm is large ..................................................................................... 40-679
H-12 Hydraulic drift of bucket is large ................................................................................. 40-681
H-13 Time lag of work equipment is large ........................................................................... 40-682
H-14 When part of work equipment is relieved singly, other parts of work equipment
move ................................................................................................................. 40-684
H-15 One-touch power maximizing function does not work .................................................. 40-685
H-16 Machine push up function does not work.................................................................... 40-686
H-17 In combined operation of work equipment, equipment having heavier load moves
slower................................................................................................................ 40-687
H-18 In combined operations of swing and boom RAISE, boom rising speed is low................ 40-688
H-19 In combined operations of swing and travel, travel speed drops largely......................... 40-689
H-20 Machine does not travel straight ................................................................................ 40-690
H-21 Travel speed is too low ............................................................................................. 40-693
H-22 Machine is hard to steer or travel power is low ............................................................ 40-695
H-23 Travel speed does not change, or travel speed is too low or high.................................. 40-698
H-24 One of tracks does not run ........................................................................................ 40-699
H-25 Upper structure does not swing in both right and left directions..................................... 40-701
H-26 Upper structure does not swing in only one direction. .................................................. 40-702
H-27 Swing acceleration or swing speed is low in both directions (right and left) .................... 40-703
H-28 Swing acceleration performance is poor or swing speed is slow in only one
direction............................................................................................................. 40-704
H-29 Upper structure overruns remarkably when it stops swinging in both directions (right and
left).................................................................................................................... 40-705
PC360LC-10 40-7
40 Troubleshooting
Table of contents
H-30 Upper structure overruns excessively when it stops swinging in only one
direction............................................................................................................. 40-706
H-31 Shock is large when upper structure stops swinging.................................................... 40-707
H-32 Large unusual noise is heard when upper structure stops swinging .............................. 40-708
H-33 When swing holding brake is applied, hydraulic drift of swing is large............................ 40-709
H-34 When swing holding brake is released, hydraulic drift of swing is large.......................... 40-710
H-35 When additional attachment is installed, attachment circuit is not switched.................... 40-711
H-36 Oil flow in attachment circuit cannot be controlled ....................................................... 40-712
Troubleshooting of engine (S-mode)......................................................................................... 40-713
Information contained in troubleshooting table (S mode)...................................................... 40-713
S-1 Engine does not crank when starting switch is turned to START position......................... 40-714
S-2 The engine cranks but exhaust smoke does not come out ............................................. 40-715
S-3 Fuel is being injected but engine does not start (incomplete combustion: engine cranks but
does not start) .................................................................................................... 40-716
S-4 Startability is poor....................................................................................................... 40-717
S-5 Engine does not pick up smoothly ............................................................................... 40-719
S-6 Engine stops during operation ..................................................................................... 40-721
S-7 Engine runs rough or is unstable ................................................................................. 40-723
S-8 Engine lacks power .................................................................................................... 40-724
S-9 KDPF gets clogged in a short time ............................................................................... 40-726
S-10 Engine oil consumption is excessive .......................................................................... 40-728
S-11 Engine oil becomes contaminated early...................................................................... 40-729
S-12 Fuel consumption is excessive .................................................................................. 40-730
S-13 Oil is in coolant (or coolant spurts or coolant level goes down)...................................... 40-731
S-14 Oil pressure drops .................................................................................................... 40-732
S-15 Fuel mixes into engine oil.......................................................................................... 40-733
S-16 Water mixes into engine oil (milky) ............................................................................. 40-734
S-17 Coolant temperature rises too high (overheating) ........................................................ 40-735
S-18 Unusual noise is heard ............................................................................................. 40-736
S-19 Vibration is excessive ............................................................................................... 40-737
S-20 Air cannot be bled from fuel circuit ............................................................................. 40-738
S-21 Frequent active regeneration..................................................................................... 40-739
S-22 Active regeneration takes time................................................................................... 40-740
S-23 White smoke is exhausted during active regeneration ................................................. 40-741
40-8 PC360LC-10
40 Troubleshooting
Related information on troubleshooting
Related information on troubleshooting (ALL-5100-001-A-00-A)
Troubleshooting points (ALL-5130-42A-A-00-A)
(Rev. 2012/11)
k Place the machine on a level ground, and make sure that the frame lock bar, chocks, and parking
brake are applied.
k When performing the operation with two or more service technicians, keep strictly to the agreed
signals, and do not allow any unauthorized person to come near.
k Ifthe radiator cap is removed when the engine is hot, hot water may spurt out and cause burns, so
wait for the engine to cool down before starting troubleshooting.
k Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
k Before disconnecting wiring, remove the key and turn the battery disconnect switch to OFF
position.
k When removing the plug or cap from a component which is under pressure of oil, water, or air,
always release the internal pressure first. When installing measuring equipment, be sure to
connect it properly.
k Drain approximately 10l

l of coolant beforehand, because you may get scalded by hot water
spurting out from mounting location of coolant temperature sensor when removing radiator cap
during checking and replacing coolant temperature sensor.
k When performing checking and replacement of engine oil pressure sensor (switch), open oil filler
port, and check that engine oil temperature cools down enough not to get scalded.
k Loosen the oil filler cap of the hydraulic tank to release the pressure in the hydraulic tank. For
details, see Testing and adjusting "Releasing remaining pressure in hydraulic circuit" when
checking and replacing oil temperature sensor and oil pressure sensor. Check the code with
monitoring function and display the hydraulic oil temperature, then check that the temperature is
40°C or lower and cool enough not to burn.
Troubleshooting denotes to locate the primary cause, fix the trouble without delay and prevent its recurrence.
Despite the importance of understanding the structure and operation of the target system in troubleshooting,
you should be aware how interviewing with the operator concerned can facilitate in roughly identifying the
cause of the given undesirable symptom.
1. When performing troubleshooting, do not hurry to disassemble the components.
If components are disassembled immediately after any failure occurs:
• Parts that have no connection with the failure or other unnecessary parts will be disassembled.
• It will become impossible to find the cause of the failure.
It will also cause a waste of manhours, parts, or oil or grease, and at the same time, will also lose the
confidence of the user or operator.
For this reason, when performing troubleshooting, it is necessary to perform thorough prior investigation
and to perform troubleshooting in accordance with the fixed procedure.
2. Points to ask the user or operator
1) Have any other problems occurred apart from the problem that has been reported?
2) Was there anything strange about the machine before the failure occurred?
3) Did the failure occur suddenly, or were there problems with the machine condition before the failure?
4) Under what conditions did the failure occur?
5) Had any repairs been performed before the failure? When were these repairs performed?
6) Has the same kind of failure occurred before?
3. Check before troubleshooting
1) Is there any sign of irregularities of the machine?
2) Make checks before starting day's work.
PC360LC-10 40-9
40 Troubleshooting
3) Make checks of other items.

4) Check other maintenance matters which can be checked externally and are considered to be
necessary.
4. Checking failure
Check the extent of the failure by yourself, and judge whether it is a real failure or a problem with the
method of operation, etc.
a When operating the machine to reenact the troubleshooting symptoms, do not perform any inspection
or measurement that may make the problem worse.
5. Troubleshooting
Use the results of the investigation and inspection in Items 2 to 4 to narrow down the probable causes of
the failure, then use the troubleshooting flowchart to locate the failure exactly.
a The basic procedure for troubleshooting is as follows.
1) Start from the simple points.
2) Start from the most likely points.
3) Investigate other related parts or information.
6. Measures to remove root cause of failure
Fixing a trouble in hand does not necessarily prevents its recurrence unless the primary cause is
eliminated. To that end, you must locate and eliminate the primary cause behind the given failure.
40-10 PC360LC-10
40 Troubleshooting
Sequence of events in troubleshooting (ALL-5140-42A-A-00-A)
(Rev. 2011. 7)
PC360LC-10 40-11
40 Troubleshooting
40-12 PC360LC-10
40 Troubleshooting
Checks before troubleshooting (PC400-5150-208-A-00-A)
No. Item Criterion Remedy

1 Check for abnormal sounds and smells – Repair
2 Check for dirt around engine – Remove
3 Check for water leakage around engine – Repair
4 Check for oil leakage around engine – Repair
5 Check for leakage from fuel line – Repair
a: Engine, lubricating oil and coolant
6 Check of radiator for clogging – Remove

7 Check of level and type of fuel – Refilling of oil
8 Check for foreign matter in fuel – Clean and drain
9 Check of fuel pre-filter – Replace
10 Check of fuel main filter – Replace
Between
11 Check of level (in oil pan) and type of engine oil Refilling of oil
H and L
Between
12 Check of coolant level (in sub tank) Refill with coolant
H and L
Air
cleaner
clogging
monitor is
13 Check of air cleaner for clogging not Clean or replace
displayed
on
machine
monitor
1 Check for abnormal sounds and smells – Repair
Check for oil leakage – Repair
b: Hydraulic and mechanical equipment
2
Check of hydraulic oil level Between Refilling of oil
3
H and L
4 Check of hydraulic oil strainer – Clean or replace
5 Check of hydraulic oil filter – Replace
Check of swing machinery case oil level Between Refilling of oil
6
H and L
7 Check of damper case oil level – Refilling of oil
8 Check of final drive case oil level – Refilling of oil
9 Performing air bleeding operation – Bleeding air
Retighten or
1 Check of battery terminal for looseness and corrosion –
replace
Retighten or
c: Electrical equipment
2 Check of alternator terminal for looseness and corrosion –

replace
Retighten or
3 Check of starting motor terminal for looseness and corrosion –
replace
4 Check of battery voltage (with engine stopped) 20 – 30 V Charge or replace
Check of battery electrolyte level Between Add or replace
5
H and L
6 Check of wiring harness for discoloration, burn and cover peeling – Repair or replace
7 Check of wiring harness for release from clamp and sagging – Repair
8 Check of grounding – Repair
9 Check for loose connector and damaged lock – Repair or replace
PC360LC-10 40-13
40 Troubleshooting
No. Item Criterion Remedy

10 Check of connector pin for corrosion, bends and deformation – Repair or replace
Dry, clean or
11 Check for water and foreign matter in connector –
replace
c: Electrical equipment
12 Check of wiring harness for open or short circuit – Repair or replace

13 Check of fuse for blowing out and corrosion – Replace
After
several
Check of alternator voltage (When engine speed is medium or minutes
14 higher) Replace
operation:
27.5 –
29.5 V
Check of battery relay operation sound (when starting switch is
15 turned to ON or OFF position) – Replace
16 Check and cleaning of camera – Clean or repair
1 Check of undercarriage – Repair
d: Exterior parts
2 Check of handrails and steps – Repair
3 Check of mirrors – Clean or repair
1 Check of gauges and monitors – Clean or replace

e: Interior parts
2 Check of seat belt – Repair
40-14 PC360LC-10
40 Troubleshooting
Inspection procedure before troubleshooting (ALL-5150-001-A-00-A)
Walk-around check (PC300-5150-289-A-00-A)
Before starting the engine, look around and under the machine to check for any loose nuts or bolts, leakages
of oil, fuel or coolant, and check the condition of the work equipment and hydraulic system.
Check the connectors for looseness, the wiring harnesses for play, and the hot parts for accumulated dust.
k Accumulated combustibles around hot engine parts such as the engine, KDPF, and turbocharger,
etc. and fuel or oil leakages may cause a machine fire. Be sure to check thoroughly and repair any
failures.
a a1 and a2, —, b1, b2, — refer to the Nos. in the table on the previous page.
a1. and b1. Check for unusual noise and smell
Check for unusual sounds and smells.
Some causes of unusual sounds and smells can damage the machine if they are left as they are. Therefore,
stop the machine immediately when you find such abnormalities.
a2. Check around engine and dirt removal
Check and remove any accumulated dirt around the engine and any combustibles (dead leaves, twigs, etc.)
on hot engine parts such as the KDPF, turbocharger, etc.
a3. Check for water leakage around engine
a4. Check for oil leakage around engine
Check for any oil leaks from the engine and any water leaks from the cooling system. If any of them is
defective, repair them.
a5. Check for leakage from fuel line
Check for any fuel leaks and damaged hoses and tubes. If any of them is defective, repair them.
a6. Check of radiator and dirt removal
Check and remove any accumulated dirt and combustibles (dead leaves, twigs, etc.) around the radiator.
For removal of dirt from the radiator, see the Operation and Maintenance Manual, "Cleaning and testing of
radiator fins, oil cooler fins, aftercooler fins, fuel cooler fins and air conditioner condenser fins (machine with
the air conditioner)".
b2. Check of work equipment, cylinders, linkage and hoses for breakage, wear and clearance
Check the work equipment, cylinders, linkage and hoses for cracks and excessive wear, check that the
clearances in them are within the normal range, and then repair any failures.
b3. Check of hydraulic equipment, hydraulic tank, hoses and joints for oil leakage
Check and repair any oil leaks.
b9. Performing air bleeding
For the procedure for bleeding air from the fuel system, see Testing and adjusting, "Bleeding air from fuel
circuit".
For the procedure for bleeding air from the hydraulic equipment, see Testing and adjusting, "Bleeding air from
each part".
c16. Check and cleaning of rear view camera
Check the rear view camera for any defect, and repair any failures.
d1. Check of undercarriage (track, sprocket, idler and guard) for defect, wear, loose bolts and oil
leakage from roller
Repair any failures.
d2. Check of handrails and steps for defect and loose bolts
Repair any failures and retighten any loose bolts.
d3. Check and cleaning of rear view mirrors
Check for and repair any defective and broken rear view mirrors.
Clean the mirror surfaces and adjust their angles so that the operator can see the area behind him at the
operator's seat.
PC360LC-10 40-15
40 Troubleshooting
e1. Check of gauges and monitors for defect

Check the gauges and monitors inside the operator cab. If any of them is defective, replace it.
Clean up the surfaces.
e2. Check of seat belt and mounting hardware
Check the hooks, locks and hook fittings for damage. If any of them has a problem, repair the damage.
Testing in accordance with testing procedure (PC300-5150-280-A-00-A)
a: Engine, lubricating oil, and coolant
a7. Check of fuel level and type
k Fuel is highly flammable and dangerous.
Never bring flames near fuel.
k When adding fuel, never spill it or let it

overflow.
k Wipe off any spilled fuel. If fuel spills over

soil or sand, remove all the fuel and soil or
sand together.
1. Turn the starting switch to ON position and

check the fuel level with fuel level gauge (1) on
the monitor panel.
After checking, turn the switch back to OFF
position.
• If breather hole (3) in the oil filler cap is

clogged, the pressure in the tank decreases
and fuel may not be supplied. To prevent this,
2. If the fuel level is low, open fuel filler cap (F) of clean the breather hole.
the fuel tank and add fuel through the oil filler
port to the necessary level, referring to the
position of float gauge (G).
3. After adding fuel, push float gauge (G) straight
down with fuel filler cap (F), and tighten fuel filler
cap (F) securely while taking care the float
gauge (G) is not caught in tab (2) of fuel filler cap
(F).
a8. Check of foreign material in fuel

1. Open the side cover on the rear right of the
machine.
2. Prepare a container below drain hose (1) to
receive the fuel.
40-16 PC360LC-10
40 Troubleshooting
3. Turn drain valve (2) to "OPEN" position (O) to 2. It is possible to judge the water level and amount
discharge the sediment and water in the bottom of sediment by looking through transparent cap
together with the fuel. (2). If there is any water or sediment collected at
4. When only the clean fuel flows out, turn drain the bottom, place a container to catch the drain
valve (2) to "CLOSE" position (S). water under drain hose (3).
5. Close the side cover. 3. Loosen drain valve (4) to drain the water.
4. If drain hose (3) starts to discharge fuel, close
drain valve (4) immediately.
a9. Check of fuel prefilter

k Immediately after the engine is stopped, its
parts and oil are still very hot, and may cause a This machine is equipped with sensor which
burn injury. Accordingly, wait until all parts detects water accumulated in the transparent
have cooled down before starting the work. cap (2).
k High pressure is generated inside the engine a Drain the water when water separator
fuel piping system when the engine is monitor (5) lights up in red on machine
running. Stop the engine and wait at least 30 monitor, since it shows water accumulated in
seconds until the inner pressure is released the transparent cap (2).
and then replace the filter .
k Never bring flames near fuel.
a A special filter with high-efficiency filtering

properties is adopted for Komatsu genuine fuel
filter cartridges. Be sure to use Komatsu
genuine parts when replacing.
a The common rail fuel injection system used on
this machine consists of more precise parts than
those in the conventional injection pump and
nozzles. If any cartridge other than a Komatsu
genuine fuel filter cartridge is used, foreign
material may enter and it may cause problems in a Water separator monitor may not light up if
the injection system. Do no use substitute parts. the water accumulated in transparent cap (2)
a During testing or maintenance of the fuel system, is frozen. Or, water separator monitor (5)
take extreme care not to allow any foreign may suddenly light up when the frozen water
material to enter the fuel system. If any dust or is melted after engine is started due to
other material sticks to any part, wash the part temperature raised around fuel prefilter (1).
thoroughly with clean fuel. Drain water frequently at cold weather even
when water separator monitor (5) is not lit.
• Prepare a container to receive drained oil.
• Prepare a filter wrench. a If water in transparent cap (2) is frozen, drain
Check of water separator, and drainage of water water only after confirming that it has
and sediments completely melted.
1. Open the side cover.
• The water separator is integrated with fuel
prefilter (1).
PC360LC-10 40-17
40 Troubleshooting
a If you cannot visually identify the presence of

water due to stains on transparent cap (2),
clean transparent cap (2) when replacing fuel
prefilter cartridge (1).
a When you have removed drain valve (4) for
the above cleaning process, coat the O-ring
with grease and tighten drain valve until it
touches the bottom.
Replace fuel prefilter cartridge
1. Turn valve (1) at the bottom of the fuel tank to
the "CLOSE" (S) position.
9. When installing the transparent cap, apply a thin

film of oil to the O to ring, set it against the
sealing surface of filter cartridge (4), and then
tighten the transparent cap by turning 1/4 to 1/2
turn.
a If the transparent cap is fastened too much,
the O-ring will be damaged and this leads to
leakage of fuel. If it is too loose, fuel will also
leak from gaps of the O-ring. Therefore, be
sure to observe the fastening angle.
10.Clean the filter holder, fill the new filter cartridge
with clean fuel, apply a thin film of oil to the O-
ring, and then install the new filter cartridge on
the filter holder.
a Be sure to add fuel through 8 small holes (A)
on the dirty side without removing center cap
(B).
a After adding fuel, remove cap (B) and install
the fuel filter.
a Always fill with clean fuel. Be careful not to let
any dirt or dust get into the fuel. In particular,
center portion is the clean side, so do not
remove cap (B) when adding fuel. Be careful
not to let dirt or dust get into the center clean
2. Open the side cover on the right side of the side part.
machine.
3. Place a container under the fuel prefilter
cartridge to receive the fuel.
4. Loosen drain valve (2) and drain water and
sediments from transparent cup (3), and also
drain all the fuel from filter cartridge (4).
5. Remove connector (5). Wrap the removed
connector with a plastic bag to protect it from
fuel, oil and water.
6. Turn transparent cap (3) by using the filter
wrench, and remove it. (This cap is reused.)
7. Using the filter wrench, turn filter cartridge (4) to
remove.
8. Install currently removed transparent cap (3) to 11.When installing, tighten it by 3/4 turn after the O-
the bottom of the new filter cartridge. ring comes in contact with the sealing surface of
a At this time, replace O-ring (6) with a new the filter holder.
one.
40-18 PC360LC-10
40 Troubleshooting
a If the filter cartridge is over tightened, fuel will a During testing or maintenance of the fuel system,
leak because the O-ring is damaged. If the take extreme care not to allow any foreign
filter cartridge is not tightened sufficiently, material to enter the fuel system. If any dust or
fuel will also leak through the clearance of other material sticks to any part, wash the part
the O-ring. Therefore, observe the tightening thoroughly with clean fuel.
angle. • Prepare a container to receive drained oil.
a When using a filter wrench for tightening, • Prepare a filter wrench.
take care not to leave flaws or dents on the 1. Turn valve (1) at the bottom of the fuel tank to
filter. the "CLOSE" (S) position.
12.Make sure that drain valve (2) is securely
closed.
13.Remove the plastic bag wrapping connector (5),
then connect connector (5).
a If water gets on connector (5), the sensor
may malfunction and the water separator
monitor may light up. When removing
connector (5), be extremely careful not to let
water attach to connector.
a If water attaches to connector (5), dry it
completely before connecting it.
a10. Check of main filter

parts and oil are still very hot, and may cause
burn injury. Accordingly, wait until all parts 2. Open the side cover on the right side of the
have cooled down before starting the work. machine.
3. Place a container under the filter cartridge to
k High pressure is generated inside the engine receive the fuel.
fuel piping system when the engine is 4. Using the filter wrench, rotate filter cartridge (2)
running. Stop the engine and wait at least 30 to remove.
seconds until the inner pressure is released
and then replace the filter . a After removing the filter cartridge, fuel falls in
drops from the filter head.
k Never bring flames near fuel. In order to prevent fuel from flowing out, be
sure not to leave the machine without the
a A special filter with high-efficiency filtering filter cartridge.
properties is adopted for Komatsu genuine fuel
filter cartridges. Be sure to use Komatsu
genuine parts when replacing.
a The common rail fuel injection system used on
this machine consists of more precise parts than
those in the conventional injection pump and
nozzles. If any cartridge other than a Komatsu
genuine fuel filter cartridge is used, foreign
material may enter and it may cause problems in
the injection system. Do no use substitute parts.
PC360LC-10 40-19
40 Troubleshooting
7. Turn valve (1) at the fuel tank bottom to "OPEN"

(O) position.
8. Bleed air according to the following procedure.
1) Fill up the fuel tank with fuel (to the level
where the float is at the highest position).
2) Loosen feed pump knob (4) and draw it out
once, then push and pull several times until
its movement becomes stiff.
• You do not need to remove the plugs at
the head of the fuel pre-filter and fuel
main filter.
• If fuel is used up, bleed air by operating
5. Clean the filter holder. Apply a thin film of oil to feed pump knob (4) in the same manner.
the packing of the new filter cartridge and install
the cartridge to the filter holder.
a Replace inside seal (3) with a new one.
3) Push in and tighten feed pump knob (4).

9. After replacing the filter cartridge, run the engine
at low idle for approximately 10 minutes.
10.Check the filter seal surface for fuel leakage. If
a Do not fill the new filter cartridge with fuel. there is any leakage of fuel, check the fastening
condition of the filter cartridge. If the fuel still
a Remove cap (A) at the center, and then leaks, follow Steps 1 to 4 to remove the filter
install the filter cartridge. cartridge. If any damage or foreign material is
found on the O-ring, replace the cartridge with a
new one, then proceed to Step 5 and later.
a11. Check of engine oil level (in oil pan) and
type
burn injury. Accordingly, wait until all parts
have cooled down before starting the work.
a When checking the oil level after the engine has

been operated, wait for at least 15 minutes after
stopping the engine.
6. When installing the filter cartridge, tighten it by 3/ a If the machine is at an angle, make it level
4 turn after the O-ring comes in contact with the before checking.
sealing surface of the filter holder. a When the ambient temperature is low, water or
a If the filter cartridge is over tightened, fuel will emulsified matter may stick to the oil level gauge,
leak because the O-ring is damaged. If the oil filler cap, etc. or the drained oil may be milky
filter cartridge is not tightened sufficiently, white because of water vapor in the blowby gas.
fuel will also leak through the clearance of However, if the coolant level is normal, it is not a
the O-ring. Therefore, observe the tightening problem.
angle. 1. Stop the engine.
2. Open the engine hood.
40-20 PC360LC-10
40 Troubleshooting
3. Remove oil level gauge (G) and wipe off oil on

the gauge with a cloth.
4. Insert oil level gauge (G) fully and pull it out.
5. If the oil level is between lines H and L on oil

level gauge (G), it is at the correct level.
If the oil level is below the L mark, add oil
through oil filler port (F).
a12. Check of coolant level (in reservoir tank)

k The radiator cap does not need to be opened
6. If the oil level is above line H, drain the extra for standard checks. When checking the
engine oil through drain valve (B) at the bottom coolant level, check it in reservoir tank when
of the engine oil pan and check the oil level the engine is cooled down.
again.
7. If the oil is at the correct level, tighten the oil filler k Immediately after the engine is stopped, the
cap securely and close the engine hood. coolant is still very hot and the pressure is
accumulated in the radiator.
If the cap is opened under these conditions,
you may be scalded. If you need to remove
the radiator cap, wait until the temperature
drops before you do. Then turn the cap
slowly to release the pressure and remove it
with care.
1. Open side cover on the rear left of the machine,

check the coolant level is within "FULL - LOW"
range at reservoir tank (1) (shown in the figure
below). If coolant is insufficient, add coolant up
to FULL level through water filler port at
reservoir tank (1).
2. After refilling with coolant, tighten the cap
securely.
3. If the reservoir tank is vacant, coolant may have
leaked.
If any abnormality is found in the check for
leakage, repair it immediately. If no abnormality
is found, check the level of the coolant in the
radiator. If it is low, add coolant to the radiator
and then to the reservoir tank.
PC360LC-10 40-21
40 Troubleshooting
4. If reservoir tank (1) is dirty and it is difficult to

check the coolant level, clean it.
a Until air cleaner clogging monitor (1) on monitor

panel lights up, do not clean the air cleaner
element. If you clean the element frequently
before the air cleaner clogging monitor on
machine monitor lights up, the air cleaner will not
deliver optimum performance and the cleaning
efficiency will be reduced.
a Inspection, cleaning or servicing while the
engine is running allows entry of dusts and can
damage the engine since dusts attached to the
element drop into the inner cylinder element
more frequently during the cleaning process. Be
sure to stop the engine before cleaning.
Cleaning of outer element
a.13 Check of air cleaner for clogging a Before and after cleaning, be careful not to leave
or store the element being exposed to the direct
k When using compressed air for cleaning, put
sunlight.
on personal protective items such as
protective eyeglasses, gloves, dust mask, a Replace the outer element after you have
etc. to protect yourself from dirt that will fly cleaned 6 times or it has been used for a year.
out. When replacing it, replace the inner element at
the same time, too.
k When removing the outer element from the
air cleaner body, do not forcibly pull it out, a Even when the number of cleanings of the outer
otherwise it can be dangerous. element is less than 6 times, it must be replaced
along with the inner element if air cleaner
Be careful not to fall from a high location on clogging monitor (1) indicates the red zone
unsafe scaffolding as a reaction when pulling immediately after cleaning.
out the outer element.
1. Open side cover on the rear left of the machine,
Testing remove hook (2) (3 places), and remove the
cover (3).
If air cleaner clogging monitor (1) on monitor panel
lights up on the machine monitor, clean the air
cleaner element.
40-22 PC360LC-10
40 Troubleshooting
2. When removing outer element (5), hold it and

pull it out while gently moving it up and down,
right and left.
a Be sure not to remove inner element (6).
Removing the inner element allows entry of
dusts, leading to failure of the engine.
a Do not use tools like a screwdriver.
a After removing outer element (5), check the
inner element for disengagement and tilting.
If tilted, push it back fully with your hands.
3. After removing outer element (5), cover inner a After clearing the element, throw light on its
element (6) with a clean cloth or tape to protect inside by using a light bulb to check it. If it
from dusts. has a small hole or thin part, replace it.
4. Clean dusts in inside and on cover (3) of air
cleaner body (7) by using a clean cloth or brush.
a Do not hit the element or bump it against
nearby things when cleaning it.
8. Remove the cover of cloth or tape attached to

inner element (6).
9. Check the seal of the cleaned or new element
for adhesion of dusts and oil and wipe them of, if
any.
a Do not use an element or O-ring that has
5. If any dust is attached to vacuator valve (4) been in service for a year since trying to use
installed to cover (3), remove it. them after cleaning most probably induces
troubles.
a Do not use the element if its folds or gasket
or seal are damaged.
10.Push the outer element straight backward into
the air cleaner body with your hands while
moving it up and down, right and left.
a When installing the air cleaner element, set it
in such that its cylinder bottom (side without
a hole) C comes to cover (3) side.
Installing it in an opposite direction can
induce serious troubles including damage on
the air cleaner elements and engine.
6. Blow dry compressed air (less than 0.2 MPa
{2.1kg/cm2}) from the inside of the outer element
along the folds.
7. Then blow it from outside along the folds, and
finally blow it from the inside again.
PC360LC-10 40-23
40 Troubleshooting
Replacement of element
1. Referring to "Cleaning of outer element", remove
11.Install cover (3) according to the following outer element (5).
procedure. 2. Remove inner element (6), and immediately
1) Align cover (3) with the element. install inner element (6) to air cleaner body (7).
a Install cover (3) so that vacuator (4) faces a Do not clean or reuse the inner element.
down (A) . Replace the inner element with a new one
when replacing the outer element.
2) Lock the tip of hook (2) on the protrusion of

the air cleaner body.
a Lock the tip of hooks (2) diagonally (top in such that its cylinder bottom (side without
and bottom, and right and left). a hole) C comes to cover (3) side.
a After installing cover (3), check presence Installing it in an opposite direction can
of clearance between the air cleaner induce serious troubles including damage on
body and cover (3). If any, install the the air cleaner elements and engine.
cover again. a If the outer element and cover are installed
when the inner element is securely installed,
the outer element can be damaged. Be sure
to install it securely.
12.Peel off a seal after cleaning the element each

time.
40-24 PC360LC-10
40 Troubleshooting
3. Push the outer element straight backward into a If the work equipment posture is not as
the air cleaner body with your hands while shown below, start the engine, fully retract
moving it up and down, right and left. the cylinder rods for arm and bucket at
engine low idle. Then lower the boom until
bucket teeth touch the ground, then stop the
in such that its cylinder bottom (side without
engine.
a hole) C comes to cover (3) side.
Installing it in an opposite direction can
induce serious troubles including damage on
the air cleaner elements and engine.
4. Replace O-ring (8) of cover (3) with a new one.
2. Turn the starting switch to ON position within 15

seconds from the engine stop and operate
control levers (work equipment and travel) to the
travel end in each direction to release internal
pressure.
5. Referring to "Cleaning of outer element", install 3. Open the cover on the right side of the machine,
cover (3). and check sight gauge (G). If the oil level is
6. Replace the seal (9) of cover (3) with a new one. between lines H and L, it is at the correct level.
a If the oil level is below line L, add oil through
oil filter port (F).
a Do not add oil above the H mark since it can
damage the hydraulic circuit or allow spurt of
oil.
a If oil is added above the H level, stop the
engine, wait for the oil temperature to cool
down, discharge excessive oil from drain
plug (B) under the suction tube.
b. Hydraulic and mechanical equipment

b3. Check of hydraulic oil level
k When removing the oil filler cap, the oil may

spout out. Turn it slowly to release the
internal pressure, then remove it.
1. Set the work equipment in the posture as shown

below and, after stopping the engine, check the
oil level and add new oil if necessary.
PC360LC-10 40-25
40 Troubleshooting
Since the oil level varies according to the oil b.5 Check of hydraulic oil filter
temperature, use the followings as a guide.
• Between of H and L before start of operation
(oil temperature 10 to 30°C) parts and oil are still very hot, and may cause
• During normal operation (oil temperature: 50 burn injury. Accordingly, wait until all parts
to 80°C), the oil level should be near line H. have cooled down before starting the work.
b4. Check of hydraulic oil strainer
k When you remove the oil filler cap, oil may
k Immediately after the engine is stopped, its spurt out. Be careful to rotate it slowly, and
parts and oil are still very hot, and may cause release inner pressure gradually.
have cooled down before starting the work. 1. Set the work equipment in the posture on a level
and firm ground as shown below, and stop the
k When you remove the oil filler cap, oil may engine.
spurt out. Be careful to rotate it slowly, and
release inner pressure gradually.
1. Stop the engine and remove oil filler cap (F) of

the hydraulic tank to release the internal
pressure.
2. Remove the bolts to remove cover (1).
3. When removing the bolts, keep pressing down
cover (1) since it may be flung toward you by
spring (2).
4. Pull out rod (3) from the top, and take out spring
(2) and strainer (4).
5. Remove any dirt stuck to strainer (4), then wash
it in flushing oil. If strainer (4) is damaged,
2. Remove oil filler cap (F) of the hydraulic tank to
replace it with a new one.
release the internal pressure.
6. Insert and set strainer (4) in projected portion (5)
of the tank.
7. While pressing down spring (2) with the
projection at the bottom of cover (1), install the
bolts. Tighten the mounting bolts.
3. Remove the bolts to remove cover (1).
40-26 PC360LC-10
40 Troubleshooting
When removing the bolts, keep pressing down

cover (1) since it may be flung toward you by
spring (2).
4. Remove spring (2), valve (3) and strainer (4),
and then remove element (5).
• Check the bottom of the filter case for dirt or
other material, and remove any if found. At
that time, take extreme care for any dirt or
other material not to drop into the hydraulic
tank.
5. Clean the removed parts by using cleaning oil.
6. Install new element (5).
7. Place strainer (4), valve (3) and spring (2) onto
the element.
8. Set cover (1) and install it with the mounting
bolts while pressing it by hand.
9. Tighten the mounting bolts.
10.Install oil filler cap (F).

11.To bleed air, run the engine at low idle for 10
minutes.
12.Stop the engine.
b6. Check of swing machinery case oil level
have cooled down before starting the work. b7. Check of damper case oil level
1. Remove oil level gauge (G) and wipe off oil on k Perform oil level check more than 30 minutes
the gauge with a cloth. after placing the machine on a level place.
2.
3. Pull out oil level gauge (G) and check the oil 1. Open the side cover on the right side of the
level. If the oil level is between stamped lines (H) machine.
and (L) on the oil level gauge, it is at the correct 2. Remove plug (G), and check that oil level is near
level. the bottom line of the plug hole. If it is not,
4. If the oil does not reach the (L) mark on oil level remove the cap, and refill the oil until it reaches
gauge (G), add oil through oil filler (F). to the bottom of plug (G) through oil filler port.
5. If the oil level is above line (H) of oil level gauge a If the oil level is too high, it may cause
(G), loosen drain valve (B) to drain the excessive overheating. Drain oil until it becomes
oil. specified level.
• When draining the oil, place an oil container 3. Install plug (G) and oil filler cap (F).
under drain valve (PB). 4. Close the side cover.
6. After checking the oil level and adding oil, install
oil level gauge (G) and oil filler cap (F).
PC360LC-10 40-27
40 Troubleshooting
b8. Check of final drive case oil level

k Since the oil may spurt out due to internal
pressure, rotate the plug gradually from its
side to release the internal pressure and then
remove it carefully.

• Refill capacity (right and left): 5.0 l

• Prepare a handle for the work.
1. Set the TOP mark at the top, and the line b9. Bleeding air
running on TOP mark and plug (P)
• For the bleeding air from the fuel system, see
perpendicular to the ground.
Testing and adjusting, "Bleeding air from fuel
2. Place the oil container to receive oil under plug
circuit".
(P).
• For bleeding air from the hydraulic system, see
3. Remove plugs (P) and (F) by using the handle,
Testing and adjusting, "Bleeding air from
and drain oil.
hydraulic circuit".
a Check for damages on O-ring attached to the c. Electric equipment
plugs. Replace it if necessary.
c1. Check of battery terminal for looseness and
4. Tighten plug (P) to the specified torque.
corrosion
5. Refill oil through plug (F) hole.
6. If oil flows out of the plug (F) hole, install the plug 1. Open the battery cover.
(F). 2. Check the battery cable terminals for looseness
and corrosion.
3 Tightening torque of plugs (P) and (F):
68.6 ± 9.8 Nm {7 ± 1 kgm}
k There are 2 plug (f)s. For refilling, use the

one which is easier for refilling and inner
gear is not seen through.
c2. Check of alternator terminal for looseness

and corrosion
• Check alternator terminal B for open circuit,
looseness and corrosion.
40-28 PC360LC-10
40 Troubleshooting
c3. Check of starting motor terminal for and add purified water (example: commercially
looseness and corrosion available battery fluid) to the U.L. line
• Check starting motor terminal B and terminal C immediately.
for open circuit, looseness and corrosion. 3. After adding the purified water, tighten cap (2)
c4. Check of battery voltage (with engine securely.
stopped)
• Check the battery voltage by using the battery
tester while the engine is stopped.
c5. Check of battery electrolyte level
Check before operating the machine.
k Do not use the battery if the battery
electrolyte level is below LOWER level line.
This will accelerate deterioration of the
inside of the battery and reduce the service
life of the battery. In addition, it may cause an
explosion.
k Since the battery produces combustible gas

that can explode, do not bring any open a If the fluid exceeds the UPPER LEVEL,
flame near it. remove the fluid using a dropping pipette or
others until the fluid drops to the UPPER
k Battery electrolyte is dangerous. Be careful LEVEL. When you have removed the fluid
that it does not come in contact with your from the battery, neutralize it with the baking
eyes or skin. If it does, wash it away with soda (sodium bicarbonate) and wash it away
water and contact your doctor. with a large quantity of water.
• When electrolyte level cannot be checked
a Do not add the battery fluid above the UPPER through the side face of the battery
LEVEL line. If done, the fluid may leak and the 1. Remove caps (2) from the top of battery.
coating surface may be damaged or the parts 2. Observe fluid level port (3), and check the fluid
may be corroded. level. If the fluid level is below sleeve (4), always
add the fluid (such as a commercial battery fluid)
a To avoid freezing, add the purified water (such
until it reaches the bottom of sleeve (the UPPER
as a commercial battery fluid) before starting the
LEVEL).
work in the next day.
• (A) Correct level: Since the electrolyte level
• When checking the electrolyte level through the
reaches to the sleeve bottom, the shape of
side face of the battery
the electrode plates will appear distorted due
1. Wipe and clean the battery surface, especially
to the surface tension.
around the battery level lines with a wet cloth,
• (B) Low level: Electrolyte level does not
and check to see that the battery fluid is
reach the bottom of sleeve, so pole plates
between the UPPER LEVEL and LOWER
appear straight and not bent.
LEVEL lines.
3. After adding fluid, tighten cap (2).
a Do not clean the battery with a dry cloth
since static electricity may cause an
explosion.
2. If the electrolyte level is below the center

between the U.L. and L.L. lines, remove cap (2)
PC360LC-10 40-29
40 Troubleshooting
a If the fluid exceeds the UPPER LEVEL,

remove the fluid using a dropping pipette or
others until the fluid drops to the UPPER
LEVEL. When you have removed the fluid
from the battery, neutralize it with the baking
soda (sodium bicarbonate) and wash it away
with a large quantity of water.
c6. Check of wiring harness for discoloration,
burn and cover peeling
• Check the wiring harness and cables for
discoloration and burn.
a If discolored or burnt, the circuit may be shorted
or grounded.
• Check the wiring harnesses and cables for
damage and peeling of the covers.
• If any abnormality is found, repair or replace the
wiring harness or cables.
c7. Check for coming off of wiring harness
clamp and sagging of wiring harness
• Check wiring harness for sagging and looseness
due to coming off of harness clamp
a In particular, carefully check the wiring harness
around the hot and movable parts.
• If removed from the clamp, secure it with the
clamp. • Open the side cover on the rear left of the
machine.
• Check the connection of ground terminal (T08).
c8. Check of grounding

a Be especially careful for loose ground terminals
• Check the connection of ground terminals (T04)
and corrosion.
to (T07), (T09), and (T10).
• Check the connection of ground terminal (60B)
and (T01).
• Open engine undercover under the engine.
40-30 PC360LC-10
40 Troubleshooting
a Checking of engine ground can be performed by a Use a hexagonal wrench with 4 mm width
removing the undercover under the engine. across flats.
• Check the connection of ground strap (2) of
engine controller (1).
c10. Check the connector pins for corrosion,

bending and deformation.
• Cab ground T02 • Disconnect the connectors, and check their pins
a Since (T02) is situated at the bottom on the rear for corrosion, bending, sinking than other pins,
left side of the cab and connected to (T01), it is and extension of female pins.
• If pins are defective, repair or replace them.
not particularly necessary to be checked.
a If the pins are not shiny, apply contact restorer to
them and connect and disconnect the
connectors several times to shine them. (If the
pins do not become shiny, connect and
disconnect the connectors 10 times)
c11. Check of connector for water and foreign
material insertion.
• Disconnect connectors, and check them for
insertion of water or foreign materials.
c9. Check for loose connector and damaged

lock.
• Check the connection of male and female
connectors by pulling them by hand.
• If the connection is loose, secure it.
a If any water or foreign materials are found, the

seals may be defective. Check the seals for
damage.
• If the seal is defective, repair or replace it.
• Dry the inside of the connector with a dryer.
• Check the connectors for unlocking, and check

the lock and connector housing for cracking.
• Check lock screws (5) to (7) of engine controller
(1) for looseness.
PC360LC-10 40-31
40 Troubleshooting
• A fusible link is a large-capacity fuse.

• If a fuse is corroded and coated with white
powder, or there is any play between the fuse
and fuse holder, replace the fuse.
• Replace each fuse with the one of the same
capacity.
Remove the cover at the rear right of the operator
seat, and the fuse holder is seen.
• Wipe and remove any foreign material with a

cloth or others, and blow the air to clean the
connector.
Remove the cover on the air cleaner, remove the

cover of battery relay, and the fusible link (F04) and
(F05) is seen.
c12. Check of wiring harness for open or short

circuit
• Check the connection (crimped part) between
connector pins and wiring harness.
• If the line is open as shown as (A), repair or
replace the wiring harness or cables.
c14. Check of alternator voltage (when engine

speed is medium or higher)
2. Connect the positive (+) lead of the multimeter to
alternator terminal (B) and connect the negative
(-) lead to the chassis ground.
3. Start and warm up the engine and measure the
voltage while running the engine at a medium or
a higher speed.
• If the voltage is abnormal, repair or replace
• Visually check wiring harnesses for peeling of the alternator.
harness covers and the pins for contact with c15. Check of battery relay operation sound
adjacent pins due to defective crimping. 1.
c13. Check of fuse for breakage and corrosion 2. Turn the starting switch to ON and OFF
positions, and check whether the battery relay
a When replacing a fuse, be sure to turn off the
operation sound is heard or not.
power (turn the starting switch to OFF position)
and turn the battery disconnect switch to OFF • If the operation sound is not heard, check the
position. related circuits, referring to the description of
40-32 PC360LC-10
40 Troubleshooting
troubleshooting for E-1 described in the E

mode troubleshooting.
• If the relating circuit is normal, replace the
battery relay.
PC360LC-10 40-33
40 Troubleshooting
Preparation work for troubleshooting of electrical system (ALL-C050-001-K-01-A)
a When carrying out troubleshooting of an electric circuit related to the machine monitor, engine controller,
pump cont roller, or KOMTRAX communication MODEM, expose the related connectors according to the
following procedure.
a Disconnect and connect the connectors, which have a special locking device, according to the following
procedure.
Preparation (PC300-C050-42C-K-00-A)
1. Machine monitor
1) Remove 3 mounting screws of cover (1).
a One of the 3 screws is covered with cap
(2).
a Disconnect connector P31 of sunlight
sensor and remove cover (1).
4) Insert or connect troubleshooting T-adapters

to connectors CM01, CM02, and CM04 on
machine monitor (7).
2) Remove a mounting bolt and duct (6).

3) Insert a flat-head screwdriver in slit (3) and
pull it upward to remove cover (5) while
releasing lug (4).
2. Pump controller
1) Slide the operator's seat and seat stand to
the forward end.
2) Remove 5 mounting bolts to remove cool
and hot box (9).
a While removing it, disconnect the drain
hose.
3) Remove 2 mounting bolts and 1 fastener to
remove magazine box (10).
4) Remove 3 mounting bolts to remove cover
(11).
(14).
40-34 PC360LC-10
40 Troubleshooting
6) Connect test adapters to connectors CP01 3) Lightly press part (A) on both sides of
and CP02 of pump controller (15). connector cover (1) to release tabs (B).
4) Remove connector cover (1) around tab
a The operating voltage cannot be
(C).
measured by inserting T-adapter because
it is not designed to accept T-adapter.
a Connector without connector cover

(1).
a How to disconnect connectors CP01 and
CP02
• While pressing lock (L1), turn lock
(L2) inward.
a Bar (B) comes out and the lock is
released.
• Procedure for installing connector cover

1) Push in right and left sliders (4) as far as
they go.
3. Reference
• Procedure for removing connector cover (1)
1) Cut and remove cable tie (2).
2) Move lever (3) upward.
PC360LC-10 40-35
40 Troubleshooting
4) Put tabs (B) in to install connector cover

(1).
a Right and left sliders (4) pushed in as

far as they go (left in the following
figure) 5) Replace the cut cable ties with new ones
2) Move lever (3) on connector cover (1) to bind connector cover (1) and the wiring
from the top position to the left position harness together.
(locked position) as shown in the 4. KOMTRAX terminal
following figure. 1) Slide the operator's seat and seat stand to
a (B), (C): Tab the forward end.
2) Remove 5 mounting bolts to remove cool
a If the sliders and lever are not set as and hot box (9).
shown in the following figure, the
connector is not disconnected or a While removing it, disconnect the drain
locked securely with the lever. hose.
Accordingly, check their positions 3) Remove 2 mounting bolts and 1 fastener to
again. remove magazine box (10).
(11).
(14).
3) Set tab (C) to the connector and place

connector cover (1).
a Take care that wiring harness (5) is
not caught. 6) Connect T-adapters for troubleshooting to
connectors CK01 and CK02 of KOMTRAX
terminal (15).
40-36 PC360LC-10
40 Troubleshooting
a Disconnection and connection of

connectors
Since the connectors of the ambient
pressure sensor, engine Ne speed sensor,
and engine oil pressure switch have a
special lock mechanism, disconnect them
in the order of (a) to (c), and connect
them in the order of (d) to (f) as shown in
the following figure.
Disconnection: (a) Slide the lever, (b)
unlock, and (c) disconnect the connectors.
Connection: (d) Connect the connectors,
5. Engine controller (e) engage the lock, and (f) slide the lever.
1) Open the engine hood.
2) Connect or insert T-adapter for
troubleshooting to engine controller (1)
connectors CE03, ECM J1, and ECM J2.
a Use a hexagonal wrench with 4 mm width
across flats for lock screws (L1) and (L2).
3 Lock screw:
3 ± 1Nm{0.3 ± 0.1kgm}
a For details of engine intermediate
connector (2), see step 7.
a Removal and installation of sensor body

Since a deep socket is necessary when
performing removal and installation of the
engine oil pressure switch, see "Tools for
testing, adjusting, and troubleshooting".
2) Boost pressure and temperature sensor
(BOOST PRES & IMT)
connectors
Since connectors of the boost pressure
6. Engine-related connectors and temperature sensor have a special
1) Ambient pressure sensor (AMBAIR lock mechanism, disconnect them in the
PRESSURE) order of (a) and (b) and connect them in
Engine Ne speed sensor (CRANK SENSOR) the order of (c) and (d) as shown in the
Engine Bkup speed sensor (CAM SENSOR) following figure.
Engine oil pressure switch (OIL PRESSURE Disconnection: (a) Unlock and (b)
SWITCH) disconnect the connectors.
Crankcase pressure sensor (P57)
Connection: (c) Connect the connectors
Mass air flow sensor (P55)
and (d) engage the lock.
KDPF pressure sensor (PDPF)
KDPF temperature sensor (E26)
PC360LC-10 40-37
40 Troubleshooting

connectors
Since the connectors of common rail
pressure sensor have a special lock
mechanism, disconnect them in the order
of (a) to (b), and connect them in the
order of (c) to (d) as shown in the
following figure.
Disconnection: (a) Unlock and (b)
disconnect the connectors.
Connection: (c) Connect the connectors
and (d) engage the lock.
a Removal and installation of sensor body
Since a torque wrench is necessary when
removing and installing the charge
(boost) pressure and temperature sensor,
see "Tools for testing, adjusting, and
troubleshooting".
3) Supply pump IMV solenoid (INLET
METERING VALVE)
connectors
Since connectors of the supply pump IMV
have a special lock mechanism,
disconnect them in the order of (a) and a Precautions for disconnection of
(b) and connect them in the order of (c) connectors
and (d) as shown in the following figure.
The direction of the lock for connector
Disconnection: (a) Unlock and (b) may be changed toward the difficult
disconnect the connectors. direction (facing to the bottom or to the
Connection: (c) Connect the connectors engine side) for unlocking depending on
and (d) engage the lock. the position where the sensor is screwed
in.
In such a case, turn the lock to the
direction (a) by using the needle nose
pliers with curved tip (commercially
available) [1], then the lock can be
canceled easily.
Since the lock is canceled with "click"
sound, listen to the sound and disconnect
the connectors.
4) Common rail pressure sensor (FUEL RAIL

PRESS)
40-38 PC360LC-10
40 Troubleshooting
a Precautions for connecting connectors

When connecting connectors, pay
attention not to connect the connectors
reverse.
Engage lock portion (e) on the harness
side to triangle notch portion (f). (Pay
attention not to take square guide portion
(g) on the opposite side of triangle notch
portion (f) by mistake.)
2) Lower the red lock (L1).

3) Confirm lock (L2) at the side.
a A slit is provided on one side only. (upper
side)
5) Engine coolant temperature sensor

(COOLANT TEMP)
a Disconnection and connection of connectors
Since the connectors of engine coolant
temperature sensor have a special lock
mechanism, disconnect them in the order of
(a) to (b), and connect them in the order of 4) While pinching lock (L2), lower side cover (3)
(c) to (d) as shown in the following figure. until it touches lock (L1).
Disconnection: (a) Unlock and (b) disconnect
the connectors.
Connection: (c) Connect the connectors and
(d) engage the lock.
7. Engine intermediate connector

a Disconnecting connectors
1) Remove clip (1) to release intermediate
connector OEM CONNECTION/E24 (2).
a Photo shows the state of bare engine.
a (3) is engine controller
PC360LC-10 40-39
40 Troubleshooting
5) Grab the intermediate connector body (black

part on both male and female sides) to
disconnect the connector.
40-40 PC360LC-10
40 Troubleshooting
Classification and procedure for troubleshooting (PC220-5160-40D-A-00-A)

Classification of troubleshooting
Mode Content
Display of Troubleshooting by failure code
code
E-mode Troubleshooting electrical system
H-mode Troubleshooting hydraulic and mechanical system
S-mode Troubleshooting engine
Procedure for troubleshooting

If a problem occurs in the machine, go to the corresponding troubleshooting section according to the following
procedure.
1. Troubleshooting procedure to be taken when action level and failure code are displayed on
machine monitor:
If an action level and a failure code are displayed on the machine monitor, carry out the troubleshooting for
the corresponding [Display of code] according to the displayed failure code.
a If multiple problems occur simultaneously, all the failure codes for the problems are displayed
repeatedly in order. Record all the failure codes.
2. Troubleshooting procedure to be taken when action level and failure code are not displayed on
normal screen of machine monitor:
Check a mechanical system failure code and an electrical system failure code with the abnormality record
function of the machine monitor. (See [*1])
1) If a code is recorded, carry out troubleshooting for the corresponding [Display of code] according to the
recorded code.
a If an electrical system failure code is recorded, delete all the codes once and reproduce them, and
then see if the trouble is still detected. (See [*2])
a A failure code of the mechanical system cannot be deleted.
a If abnormality related to air conditioner is displayed in electrical system abnormality record, perform
"Check with self-diagnosis" in "Air conditioner".
2) If no failure code is recorded in the abnormality record, a failure that the machine cannot find out by
itself may have occurred in the electrical system or hydraulic and mechanical system.
In this case, check the problem which seems to be a failure again and select the same problem from
the table of "Problem which seems to be failures and troubleshooting Nos.", and then carry out
troubleshooting corresponding to that problem in the [E-mode], [H-mode], or [S-mode].
3. Actions to take after failure is repaired
Referring to following page, delete all failure codes in electrical system abnormality record.
[*1]、[*2]
1. On the normal operation screen, while pressing number key [4] in the panel switch section, press [1], [2],
and [3] in this order.
2. On the service menu screen, press switch [F3] (R) in the panel switch section twice, and then select "03
Abnormality Record".
3. Press switch [F6] in the panel switch section to confirm, and then enter the "Abnormality record" screen.
PC360LC-10 40-41
40 Troubleshooting
4. Press switch [F6] in the panel switch section to confirm, and then enter the "Mechanical system failure
record" screen.
5. Press switch [F3] (R) in the panel switch section to check failure codes one by one and take record of all
information of all failure codes.
a A failure code of the mechanical system cannot be deleted.
6. Press switch [F5] (return) in the panel switch section to return to the "Abnormality record" screen.
7. Similarly to 2 and 3, enter the "Electrical system abnormality record" screen.
8. Press switch [F3] (R) in the panel switch section to check failure codes one by one and take record of all
information of all failure codes.
a If [E] is displayed on the left of a failure code, that failure code is "active" (the failure is still occurring or
normal resetting is not confirmed yet). If [E] is not displayed on the left of a failure code, that failure
code is "non-active" and disappears in the following clearing step. Accordingly be sure to take record
of that failure code.
9. While pressing number key [4] in the panel switch section, press [1], [2], and [3] in this order to enter the
"Clearing mode". (Same as 1)
10.Press switch [F2] (CLEAR) in the panel switch section.
11.Press switch [F6] in the panel switch section to clear all failure codes temporarily.
12.Press switch [F5] (return) in the panel switch section to return to the "Electrical system abnormality record"
screen. Check if there is any failure code still displayed and take record.
13.Press switch [F5] (return) in the panel switch section to return to the "Abnormality record" screen.
40-42 PC360LC-10
40 Troubleshooting
14.Take record of information of all columns.

a Similarly to the electrical system abnormality record, if "E" is displayed on the left of a failure code, that
failure code is "active"
(the failure is still occurring or normal resetting is not confirmed yet).
15.Press switch [F2] (CLEAR) in the panel switch section to clear all codes temporarily. Check if "Abnormal"
is still displayed and take record. (Same as 10 in [*1] and [*2])
16.Press switch [F5] (return) in the panel switch section to return to the "Abnormality record" screen.
PC360LC-10 40-43
40 Troubleshooting
Symptom and troubleshooting numbers (PC300-5540-441-A-00-A)
Troubleshooting
No. Symptom of failure
Index
User code and failure code
Action level is displayed on the machine monitor. Press function switch [F5] to
1 display the "Occurred error list". Follow the
The failure code is displayed on the mechanical system abnormality record troubleshooting
2 procedure for the
screen
The failure code is displayed on the electrical system abnormality record failure code.
3
screen
Troubleshooting
Index
Check items related to engine
4 Engine does not start E-1
When the starting switch is turned to the "START" position, the engine is not
5 S-1
cranked, or started
6 Engine cranks but no exhaust smoke comes out S-2
7 Fuel is being injected but engine does not start S-3
8 Starting performance is poor. S-4
9 Engine does not pick up smoothly S-5
10 Engine stops during operation S-6 、H-2
11 Engine runs rough or is unstable. S-7
12 Engine lacks power S-8
13 Exhaust gas is black (KDPF gets clogged in a short time) S-9
14 Oil is consumed much S-10
15 Oil becomes contaminated quickly S-11
16 Fuel consumption is excessive S-12
17 Oil is in coolant (or coolant spurts back or coolant level goes down) S-13
18 Oil pressure drops S-14
19 Fuel is in oil S-15
20 Coolant is in oil (milky) S-16
21 Coolant temperature rises too high (overheating) S-17
22 Unusual noise is heard S-18
23 Vibration is excessive S-19
24 Air cannot be bled from fuel circuit S-20
25 Automatic regeneration is frequent S-21
26 Active regeneration takes a long time S-22
27 White smoke is exhausted during active regeneration S-23
28 Manual preheater does not operate E-2
29 Automatic preheater does not operate E-3
30 While preheater is operating, preheating monitor does not light up E-4
31 Automatic warm-up system does not operate (in cold weather) E-24
When auto-decelerator switch is operated, auto-decelerator monitor does not
32 light up or does not go out E-25
33 Auto-deceleration does not operate or released with lever E-26
Symptom related to work equipment, swing and travel
34 All work equipment, swing, and travel do not work E-34、H-3
35 Any of work equipment, swing, and travel can not be locked E-35
36 All of work equipment, swing and travel work slow or lack power H-1
37 Engine speed lowers extremely or engine stalls H-2 、S-6
When working mode switch is operated, working mode selection screen is not
38 displayed E-27
When working mode is changed, setting of engine and hydraulic pump is not
39 changed E-28
40-44 PC360LC-10
40 Troubleshooting
Troubleshooting
Index
40 Unusual sound is heard from around hydraulic pump H-4
41 Fine control performance or response is poor H-5
Symptom related to work equipment
42 Speed or power of boom is low H-6
43 Speed or power of arm is low H-7
44 Speed or power of bucket is low H-8
45 Work equipment does not move in single operation H-9
46 Hydraulic drift of boom is large H-10
47 Hydraulic drift of arm is large H-11
48 Hydraulic drift of bucket is large H-12
49 Time lag of work equipment is large H-13
50 Other wok equipment moves when one of work equipment is relieved H-14
51 One-touch power maximizing function does not operate H-15、E-38
52 One-touch power maximizing function cannot be canceled E-39
53 When additional attachment is installed, attachment circuit is not switched H-35、E-56
54 Oil flow in attachment circuit cannot be changed H-36
55 Machine push-up function cannot be canceled E-58
56 Machine push-up function does not operate H-16、E-59
Symptom related to combined operation
57 Work equipment loaded more is slower during combined operation H-17
58 In combined operations of swing and boom RAISE, boom rising speed is low H-18
59 Travel speed drops largely in combined operation of swing and travel H-19
Symptom related to travel
60 Machine deviates during travel H-20
61 Travel speed is low H-21
62 Machine is not steered well or steering power is low H-22
63 Travel speed does not change or travel speed is too low or high H-23、E-29、E-30
64 Travel system does not operate (only one side) H-24
65 Alarm does not sound during travel E-40
66 When the machine stops traveling, the travel alarm does not stop sounding E-41
Symptom related to swing
67 Upper structure swings neither to the right nor left H-25
68 Upper structure does not swing in only one direction H-26
69 Swing acceleration or swing speed is low in both directions (right and left) H-27
Swing acceleration performance is poor or swing speed is slow in only one
70 H-28
direction
Upper structure overruns remarkably when it stops swinging in both directions
71 (right and left) H-29
Upper structure overruns excessively when it stops swinging in only one
72 H-30
direction
73 Large shock is made when upper structure stops swinging H-31
74 Large unsual noise is heard when upper structure stops swinging H-32
75 When the swing holding brake is applied, hydraulic drift of swing is large H-33
76 When the swing holding brake is released, hydraulic drift of swing is large H-34
When swing holding brake cancel switch is set to the CANCEL position,
77 machine cannot swing E-36
When swing holding brake cancel switch is set to the NORMAL position, swing
78 holding brake does not operate E-37
Symptom is related to machine monitor
When starting switch is turned to ON position, machine monitor displays
79 nothing. E-5
When starting switch is turned to the ON position (with engine stopped),
80 engine oil level monitor lights up yellow E-6
PC360LC-10 40-45
40 Troubleshooting
Troubleshooting
Index
When starting switch is turned to the ON position (with engine stopped),
81 radiator coolant level monitor lights up yellow E-7
82 Engine coolant temperature monitor lights up white while engine is running E-8
83 Hydraulic oil temperature monitor lights up white while engine is running E-9
84 While engine is running, charge level monitor lights up E-10
85 Fuel level monitor lights up red while engine is running E-11
86 Air cleaner clogging monitor lights up yellow while engine is running E-12
87 Engine coolant temperature monitor lights up red while engine is running E-13
88 Hydraulic oil temperature monitor lights up red while engine is running E-14
89 Engine oil pressure monitor lights up red while engine is running E-15
90 Fuel level gauge does not move from "E" or "F" position E-16
Fuel level gauge displays the different level from the actual fuel level (displays
91 other than "E" or "F") E-17
92 Engine coolant temperature gauge does not move from "C" or "H" position E-18
Engine coolant temperature gauge displays the different temperature from the
93 actual coolant temperature (displays other than "C" or "H") E-19
94 Hydraulic oil temperature gauge does not move from "C" or "H" position E-20
Hydraulic oil temperature gauge displays the different temperature from the
95 actual oil temperature (displays other than "C" or "H") E-21
96 Machine monitor does not display some items E-22
97 Function switch does not work E-23
98 Alarm buzzer cannot be canceled E-31
99 When starting switch is at OFF position, service meter is not displayed E-32
100 Machine monitor cannot be set in service mode E-33
101 The horn does not sound E-42
102 Horn does not stop sounding E-43
103 When wiper switch is operated, wiper monitor does not light up or go out E-44
104 When wiper switch is operated, windshield wiper does not operate E-45
105 When window washer switch is operated, window washer does not operate E-46
"Testing and
Air conditioner does not operate normally (including failure codes related to air troubleshooting
106 conditioner)
procedure" in Chapter
80
107 Monitoring function does not display lever control signal normally E-47 ～ E-55
Others
108 KOMTRAX system does not operate properly. E-57
40-46 PC360LC-10
40 Troubleshooting
Information in troubleshooting table (ALL-5170-421-A-01-A)
(Rev. 2011/12)
a The following information is summarized in the troubleshooting table. Before performing troubleshooting,
understand that information fully.
Action level Failure code
Display on Failure name displayed on the Abnormality Record screen
Display on Failure
machine of the machine monitor
machine monitor
monitor
Detail of Description of the failure detected by the machine monitor or controller
failure
Action of An action that is performed to protect the system and devices when a failure is detected by
controller the machine monitor or controller
Problem on A problem that appears as a failure on the machine as a result of an action (above) that is
machine performed by the machine monitor or controller.
Related Information on occurred failure or troubleshooting
information
No. Cause Procedure, measuring location, criteria and remarks
1 Defective — <Contents of description>
Open or short circuit in wiring • Procedure
2
harness • Measuring location
Open circuit in wiring harness
a "Between A and B" denotes measuring values such as voltage
3 (wire breakage or defective and resistance between A and B.
contact of connector)
Ground fault in wiring harness a "Between A and ground" means the measurement of voltage,
4 resistance or others between terminal A and the place which has
(contact with ground circuit) a continuity with chassis frame such as unpainted hexagonal
5 Hot short circuit head bolt or bolt hole which has no rust, etc.
• Criteria to judge probable causes (standard value), remarks
<How to use troubleshooting sheet>
• Perform troubleshooting procedures in numerical order.
• If the check result does not meet the criteria, the probable cause
described on the left column is the actual cause of the failure.
• If the check result meet the criteria and there is no specific
instruction, proceed to the next step (cause).
• If a defect is found and repaired, check that the defect has been
corrected.
<Failures in wiring harness>
Short circuit in wiring harness
6 • Open circuit
Connection of connector is defective or wiring harness is broken.
• Ground fault
A harness not to be connected to the ground (earth) circuit comes
into contact with the ground (earth) circuit or chassis accidentally.
• Hot short circuit
A harness not to be connected to the power circuit comes into
contact with the power circuit accidentally.
• Short circuit
An independent wire in the harness erroneously comes into contact
with another independent wire.
(poor insulation at connector and others)
PC360LC-10 40-47
40 Troubleshooting

<Precautions for troubleshooting>
(1) Connector number indication method and handling of T-adapter
For troubleshooting, insert or connect T-adapters as follows unless
otherwise specified.
• When "male" or "female" is not indicated with a connector number,
disconnect the connector, and insert T-adapter between the male
and female connectors.
7 Defective controller • When "male" or "female" is indicated with a connector number,
disconnect the connector, and connect T-adapter to the male or
female connector.
(2) Pin number description sequence and tester lead handling
For troubleshooting, connect the positive (+) and negative (-) leads as
shown below unless otherwise specified.
• Connect the positive (+) lead to pin or wire indicated first.
• Connect the negative (-) lead to a pin or wire indicated second.
Related circuit diagram

This is the excerpted circuit diagram related to
troubleshooting
• The circuit diagram contains the connector Nos.,
pin Nos., and connector colors related to the
failure.
• The "/" in a connector number is either:
1) An abbreviation (of more than three letters)
Example: T/C (Torque Converter)
2) Different connector number at male and female
sides
Example: BREAK OUT/E24
• The circuit diagram contains the destination or
source of the branch line in a wiring harness.
• The arrow (io) indicates a rough installation
position on the given machine.
• NO: Normally Open
• NC: Normally Closed
• Signal names such as GND and 24 V are included
in addition to connector numbers at junctions, etc.
in circuit diagrams.
• Except for GND and 24 V, a signal name indicated
at a junction, etc. shows that the wire is connected
to another junction or controller at where the same
signal name is indicated.
40-48 PC360LC-10
40 Troubleshooting
Troubleshooting method for open circuit in wiring harness of pressure

sensor system (D65-E720-42A-P-00-A)
a Since the pressure sensors consist of not only resistor but also electronic circuit components such as
amplifiers they have variation in measured value and their own polarities. So troubleshooting must be
performed carefully.
Failure codes applicable to this diagnosis
• CA123: Charge air pressure sensor low error
Procedure
1. Measure and record resistance of pressure sensor unit.
1) Disconnect pressure sensor connector (1) and connect socket (2) to the sensor side connector.
2) Measure resistances R1 and R2 between pins.
a If the polarities of multimeter probes to apply are reversed, measured values may change.
Therefore, when measuring the resistances in steps 1 and 2, apply the multimeter probes to the
pressure sensor connector so that their polarities match those of the sensor.
a If the measured value is infinite, take measurements by applying the probes of the opposite
polarities and record the finite value obtained as a measured value.
a Since the measured values may be dispersed, take several measurements.
The cause of this dispersion appears to be an electric charge in a sensor. Take measurements
several times in steps 1 and 2. Consider this dispersion when judging whether or not the wiring
harness is open in step 3.
2. Measure and record the resistance of the wiring harness between the pressure sensor and engine
controller connected.
1) Since 5 V power supply to the pressure sensor is supplied to other sensors, disconnect other sensor
connectors first. (*)
2) With the pressure sensor to measure connected, disconnect connector (3) on the engine controller
side, and connect T-adapter (4) to the wiring harness side connector.
3) Connect T-box (5) to T-adapter (4) and measure resistances R1' and R2' between respective pins.
3. Judging open circuit
If there is an "apparent difference" between resistances R1 and R2 measured in step 1 and resistances
R1' and R2' measured in step 2, the "wiring harness is open".
a "Apparent difference" means a difference of 10 or more times.
PC360LC-10 40-49
40 Troubleshooting
List of pressure sensor measuring locations and reference values
Measuring location at Measured internal

Sensor sensor pin resistance of sensor Remarks
(reference)
Charge pressure R2: between (2) and (4) Approx. 100 z Sensor is common to engine
sensor R1: between (1) and (4) Approx. 200 z models 107 and 114
*: When measuring R2', disconnect the following: (See the circuit diagram related to each failure code)
• When measuring R2' of charge pressure sensor (CA123):
Connectors of ambient air pressure sensor, CAM sensor and boost pressure sensor
Measurement record (For measuring locations, see circuit diagram related to each failure code.)
Sensor + Wiring harness
Sensor unit (Measuring location on
Sensor (Measuring location on Measured value wiring harness side Measured value
sensor pin side connetor) connector of engine
controller)
R2': Between (60) and
R2: between (2) and (4)
Charge pressure (59) (*)
sensor R1': Between (15) and
R1: between (1) and (4)
(59)
40-50 PC360LC-10
40 Troubleshooting
Connector list and layout (PC300-C050-055-K-00-A)
Num-
Connector No. Model ber of Equipment name Address
pins
A13 DT 2 Intermediate connector G-9
A15 DT 2 Intermediate connector I-9
A40 DT 4 Intermediate connector L-6
A41 DT 4 Camera 2 I-2
A42 DT 4 Camera 3 I-2
A45 DT 4 Camera K-9
AC01 YAZAKI 10 Air conditioner unit X-4
AC02 SUMITOMO 4 Air conditioner unit X-5
Air conditioner compressor electromagnetic
AC03 X 1 AE-9
clutch
AMB AIR Ambient pressure sensor
FRAMATOME 3 AG-9
PRESSURE
BOOST PRESS. Boost pressure and intake manifold
SUMITOMO 4 temperature sensor AJ-2
&IMT
CAM SENSOR FRAMATOME 3 Camshaft (Bkup) speed sensor AE-7
CC01 070 14 ID key recognition controller Q-8
CE03 DRC 60 Engine controller AE-6
CK01 070 18 KOMTRAX terminal X-7
CK02 070 12 KOMTRAX terminal X-6
CM01 070 18 Machine monitor O-5
CM02 070 12 Machine monitor O-5
CM04 070 8 Machine monitor (for camera connection) O-6
COOLANT TEMP DELPHI 2 Coolant temperature sensor AF-4
CP01 AMP 80 Pump controller V-9
CP02 AMP 40 Pump controller V-8
CRANK SENSOR FRAMATOME 3 Crankshaft (Ne) speed sensor AI-2
D01 SWP 8 Diode array M-8
D02 SWP 8 Diode array M-9
D03 SWP 8 Diode array N-9
E01 Terminal 1 Electrical intake air heater AE-8
E24 FRAMATOME 24 Intermediate connector AF-6
E25 FRAMATOME 4 KDPF pressure sensor L-8
E26 FRAMATOME 4 KDPF temperature sensor K-8
ECM J1 [CE01] DRC 60 Engine controller AE-6
ECM J2 [CE02] DRC 60 Engine controller AG-6
EGR-SOL DT 2 EGR valve solenoid AJ-3
EXHAUST GAS Exhaust gas temperature sensor
FRAMATOME 2 AG-5
TEMPERTURE
EXHAUST Exhaust gas pressure sensor
FRAMATOME 3 AF-2
PRESSURE
F01 Terminal 20 Fuse box T-9
F04 L 2 Fusible link B-9
F05 M 2 Fusible link A-7
F11 Terminal 1 Slow-blow fuse A-8
F12 Terminal 1 Slow-blow fuse A-8
FUEL LIFT PUMP DT 2 Fuel feed pump AE-7
FUEL RAIL PRESS BOSCH 3 Common rail pressure sensor AJ-2
H08 M 4 Intermediate connector (speaker) AD-2
H09 M 8 Intermediate connector (cab roof) X-5
Intermediate connector (R.H. console
H14 090 22 harness) S-9
PC360LC-10 40-51
40 Troubleshooting
Num-
pins
Intermediate connector (R.H. console
H15 090 22 harness) S-9
Intermediate connector (L.H. console
H16 S 22 harness) X-3
INJECTOR #1 DT 2 Injector #1 AF-3
INJECTOR #2 DT 2 Injector #2 AF-4
INJECTOR #3 DT 2 Injector #3 AG-5
INJECTOR #4 DT 2 Injector #4 AG-5
INJECTOR #5 DT 2 Injector #5 AH-9
INJECTOR #6 DT 2 Injector #6 AI-7
INJECTOR CYL. 1&2 DT 4 Intermediate connector (injectors #1, #2) AF-2
INJECTOR CYL. 3&4 DT 4 Intermediate connector (injectors #3, #4) AH-5
INJECTOR CYL. 5&6 DT 4 Intermediate connector (injectors #5, #6) AI-9
INLET METERING Supply pump solenoid (IMV)
BOSCH 2 AF-9
VALVE
INTER-CONNECT DT 12 Intermediate connector AI-6
J01 J 20 Junction connector X-3
J02 J 20 Junction connector W-3
J03 J 20 Junction connector W-2
K01 M 2 Resistor for PC-EPC valve O-8
K02 DT 3 CAN terminating resistor 1 AH-1
L01 DT 2 Working lamp (boom) A-4
L02 DT 2 Work lamp C-6
L03 M 2 Room lamp S-9
L05 SWP 2 Intermediate connector AC-8
L09 DT 2 Working lamp (rear) H-9
L19 DT 2 System operating lamp E-1
M01 PA 10 Radio V-1
M01A – 3 Radio V-2
M01B M 3 Intermediate connector AD-2
M01C – 3 AUX (external audio input) port AC-1
M02 M 2 Speaker (L.H.) AC-8
M03 M 2 Speaker (R.H.) AB-9
M04 Terminal 2 Cigarette lighter S-9
M05 M 6 Wiper motor O-4
M06 YAZAKI 2 Window washer tank K-4
M07 090 2 Horn (high tone) F-1
M08 090 2 Horn (low tone) E-1
M09 M 2 Optional power supply connector (1) M-5
M10 M 2 Intermediate connector N-5
M11 DT 6 DC/DC converter X-5
M12 M 2 Optional power supply connector (2) X-5
M13A M 2 12 V power supply socket (1) X-7
M13B M 2 12 V power supply socket (2) X-7
M14 DT 2 Travel alarm J-3
M17 DT 2 Starting motor L-8
M18 Terminal 1 Alternator R terminal J-9
Optional power supply connector
M1A M 2 (continuous power supply) [power outlet] M-5
40-52 PC360LC-10
40 Troubleshooting
Num-
pins
M20 Terminal 1 Starting motor terminal B L-8
M21 Terminal 1 Alternator B terminal J-9
M22 Terminal 1 Alternator E terminal I-9
M24 DT 2 Fuel refill pump H-9
M35 DT 2 Heated seat V-2
M36 DT 2 Air suspension U-1
M40 X 2 Headlamp AB-1
M41 X 2 Headlamp Y-8
M80 X 3 Bucket quick coupler control box O-4
M81 X 2 Bucket quick coupler solenoid valve I-2
N08 DT 12 Service connector T-9
OEM CONNECTION FRAMATOME 24 Intermediate connector (engine harness) AF-6
OIL PRESSURE Engine oil pressure switch
FRAMATOME 1 AI-1
SWICH
P01 AMP 3 Bucket CURL pressure sensor L-3
P02 AMP 3 Boom LOWER pressure sensor L-2
P03 AMP 3 Swing (L) pressure sensor L-1
P04 AMP 3 Arm IN pressure sensor L-2
P05 AMP 3 Bucket DUMP pressure sensor L-2
P06 AMP 3 Boom RAISE pressure sensor L-1
P07 AMP 3 Swing (R) pressure sensor L-2
P08 AMP 3 Arm OUT pressure sensor L-1
Left travel FORWARD PPC oil pressure
P09 AMP 3 G-1
sensor
Left travel REVERSE PPC oil pressure
P10 AMP 3 G-1
sensor
Right travel FORWARD PPC oil pressure
P11 AMP 3 G-1
sensor
R.H. travel REVERSE PPC pressure
P12 AMP 3 G-1
sensor
Intermediate connector (service PPC
P13 X 2 pressure switch) H-1
P14 X 2 Service pressure switch (front) ―
P15 X 2 Service pressure switch (rear) ―
P17 S090 2 Dual pressure switch I-2
P18 090 2 Outside air temperature sensor H-9
P20 M 3 Fuel control dial P-8
P21 DT 2 Fuel level sensor E-8
P22 D 2 Hydraulic oil temperature sensor L-4
P23 DT 2 Air cleaner clogging sensor G-9
P24 X 2 Coolant level sensor H-9
P25 AMP 3 Front pump oil pressure sensor K-3
P26 AMP 3 Rear pump oil pressure sensor K-3
P27 DT 3 Front pump swash plate sensor L-7
P28 DT 3 Rear pump swash plate sensor L-7
P31 2 Sunlight sensor O-6
P44 DT 2 Engine oil level switch AH-1
P47 DT 2 Water-in-fuel sensor G-9
P49 AMP 3 Service pressure sensor L-4
P55 FRAMATOME 4 MAF sensor G-9
P57 FRAMATOME 3 Crankcase pressure sensor AJ-3
PDPF FRAMATOME 4 KDPF pressure sensor ―
R01 Terminal 1 Battery relay (terminal E) A-9
PC360LC-10 40-53
40 Troubleshooting
Num-
pins
R02 Terminal 1 Battery relay (terminal BR) B-9
R03 Terminal 1 Battery relay (terminal M) C-7
R04 Terminal 1 Battery relay (terminal B) C-9
R05 RELAY 5 Lamp relay T-9
R06 RELAY 5 Starting motor cut-off relay (for PPC lock) U-9
R07 RELAY 5 Starter cut-off relay (for personal code) V-9
R08 RELAY 5 Horn relay U-9
R10 RELAY 5 Rear working lamp relay U-9
R12 RELAY 5 Cab headlamp relay T-9
R15 Terminal 1 Intake air heater relay A-6
R16 Terminal 1 Intake air heater relay B-6
R17 Terminal 1 Intake air heater relay C-7
R18 RELAY 5 Relay for auto preheat V-8
Air conditioner compressor electromagnetic
R21 RELAY 5 clutch relay X-7
S01 Terminal 6 Starting motor switch P-7
S02 SWP 6 Light switch Q-8
S04 SWP 6 Swing lock switch Q-9
S05 SWP 6 Machine push-up switch Q-9
S07 SWP 6 Revolving warning lamp switch R-9
S10 Y090 2 Right knob switch (horn) P-8
L.H. knob switch (one-touch power
S11 Y090 2 maximizing switch) T-1
S14 M 3 PPC pressure lock switch U-1
S18 SWP 6 Secondary engine shutdown switch S-1
S19 DT 2 Seat belt alarm switch S-1
S21 Terminal 12 Emergency pump drive switch N-9
S22 Terminal 6 Emergency swing brake cancel switch N-9
S25 090 16 Intermediate connector O-9
S30 S 8 Model selection connector U-9
SEGR DT 3 EGR valve position sensor AJ-4
SVGT DT 3 VGT position sensor AJ-4
T01 Terminal 2 Ground (floor frame) W-2
T02 Terminal 1 Ground (cab) AD-2
T03 M 1 Ground (radio body) T-1
T04 Terminal 1 Ground (revolving frame) I-2
T05 Terminal 1 Ground (revolving frame) I-2
T06 Terminal 1 Ground (revolving frame) H-2
T08 Terminal 1 Ground A-7
T11 Terminal 1 Ground (engine body) K-9
T12 Terminal 1 Ground (engine cylinder block) AG-6
T18 Terminal 1 Ground (floor frame) T-1
T19 Terminal 1 Ground (right console frame) R-9
TEMP1 [TDOC-IN] FRAMATOME 2 KDOC inlet temperature sensor AJ-5
TEMP2 [TDOC-OUT] FRAMATOME 2 KDOC outlet temperature sensor AJ-5
TEMP3 [TDPF-OUT] FRAMATOME 2 KDPF outlet temperature sensor AI-6
TERMINATOR PORT DT 3 CAN terminating resistor 2 AI-1
TOOL PORT DT 3 Communication connector AE-9
40-54 PC360LC-10
40 Troubleshooting
Num-
pins
V01 DT 2 PPC lock solenoid valve K-3
V02 DT 2 Swing cut-off solenoid valve K-3
V03 DT 2 Travel junction solenoid valve K-3
V04 DT 2 Travel speed increase solenoid valve J-2
V05 DT 2 Swing holding brake solenoid valve J-1
V06 DT 2 Machine push-up solenoid valve J-1
V07 DT 2 Attachment selector solenoid valve K-1
V08 DT 2 2-stage relief solenoid valve K-1
V11 D 2 Front pump PC-EPC valve L-7
V12 D 2 Rear pump PC-EPC valve L-7
V19 D 2 LS-EPC valve L-4
Pump merge-divider EPC valve (for main
V23 D 2 spool) J-2
Pump merge-divider EPC valve (for LS
V24 D 2 spool) J-2
V25 D 2 Variable back pressure solenoid valve K-3
V30 DT 2 Oil flow adjuster EPC valve for attachment G-1
VGT REV AMP 3 KVGT speed sensor AG-9
VGT-SOL DT 2 KVGT solenoid AJ-3
W03 X 2 Window rear limit switch AB-9
PC360LC-10 40-55
40 Troubleshooting
Layout of connector (1/6)
40-56 PC360LC-10
40 Troubleshooting
(2/6)
PC360LC-10 40-57
40 Troubleshooting
(3/6)
40-58 PC360LC-10
40 Troubleshooting
(4/6)
PC360LC-10 40-59
40 Troubleshooting
(5/6)
40-60 PC360LC-10
40 Troubleshooting
(6/6)
PC360LC-10 40-61
40 Troubleshooting
Connector contact identification (ALL-5310-030-A-00-A)
(Rev. 2012. 09)
a The terms of male and female refer to the pins, while the terms of male housing and female housing refer
to the mating portion of the housing.
40-62 PC360LC-10
40 Troubleshooting
PC360LC-10 40-63
40 Troubleshooting
40-64 PC360LC-10
40 Troubleshooting
PC360LC-10 40-65
40 Troubleshooting
40-66 PC360LC-10
40 Troubleshooting
PC360LC-10 40-67
40 Troubleshooting
40-68 PC360LC-10
40 Troubleshooting
PC360LC-10 40-69
40 Troubleshooting
40-70 PC360LC-10
40 Troubleshooting
PC360LC-10 40-71
40 Troubleshooting
40-72 PC360LC-10
40 Troubleshooting
PC360LC-10 40-73
40 Troubleshooting
40-74 PC360LC-10
40 Troubleshooting
PC360LC-10 40-75
40 Troubleshooting
40-76 PC360LC-10
40 Troubleshooting
PC360LC-10 40-77
40 Troubleshooting
40-78 PC360LC-10
40 Troubleshooting
PC360LC-10 40-79
40 Troubleshooting
40-80 PC360LC-10
40 Troubleshooting
PC360LC-10 40-81
40 Troubleshooting
40-82 PC360LC-10
40 Troubleshooting
PC360LC-10 40-83
40 Troubleshooting
40-84 PC360LC-10
40 Troubleshooting
PC360LC-10 40-85
40 Troubleshooting
40-86 PC360LC-10
40 Troubleshooting
PC360LC-10 40-87
40 Troubleshooting
40-88 PC360LC-10
40 Troubleshooting
PC360LC-10 40-89
40 Troubleshooting
40-90 PC360LC-10
40 Troubleshooting
PC360LC-10 40-91
40 Troubleshooting
40-92 PC360LC-10
40 Troubleshooting
PC360LC-10 40-93
40 Troubleshooting
40-94 PC360LC-10
40 Troubleshooting
PC360LC-10 40-95
40 Troubleshooting
40-96 PC360LC-10
40 Troubleshooting
PC360LC-10 40-97
40 Troubleshooting
40-98 PC360LC-10
40 Troubleshooting
PC360LC-10 40-99
40 Troubleshooting
T-branch box and T-branch adapter table (ALL-5330-305-A-00-A)
(Rev. 2012. 09)
a The vertical column indicates a part number of T-branch box or T-branch adapter, while the horizontal
column indicates a part number of harness checker assembly.
T-adapter kit
Identification symbol
Number of pins
Out of kit
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Part number Part name
799-601-2600 T-box (for ECONO) 21 q q q q q

799-601-3100 T-box (for MS) 37 q
799-601-3200 T-box (for MS) 37 q
799-601-3380 Plate for MS (14-pin) q
799-601-3410 Adapter for BENDIX (MS) 24 MS-24P q
799-601-3470 Case q
799-601-2710 Adapter for MIC 5 MIC-5P q q q
799-601-2720 Adapter for MIC 13 MIC-13P q q q
799-601-2730 Adapter for MIC 17 MIC-17P q q q q q q
799-601-2740 Adapter for MIC 21 MIC-21P q q q q q q
799-601-2950 Adapter for MIC 9 MIC-9P q q q q
Adapter for ECONO ECONO
799-601-2750 2 q q
2P
799-601-2760 3 q q
3P
799-601-2770 4 q q
4P
799-601-2780 8 q q
8P
799-601-2790 12 q q
12P
799-601-2810 Adapter for DLI 8 DLI-8P q q
Extension cable (ECONO ECONO
799-601-2840 type) 12 q q q
12P
799-601-2850 Case q
T-box (for DRC60, q
799-601-4350 ECONO) 60
799-601-4360 Case q
799-601-7010 Adapter for X (T-adapter) 1 q q
799-601-7020 Adapter for X 2 X2P q q q q
40-100 PC360LC-10
40 Troubleshooting
T-adapter kit
Number of pins
Out of kit
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201

799-601-7050 Adapter for SWP 6 SW6P q q q
799-601-7060 Adapter for SWP 8 SW8P q q q
799-601-7310 Adapter for SWP 12 SW12P q
799-601-7070 Adapter for SWP 14 SW14P q q
799-601-7320 Adapter for SWP 16 SW16P q
799-601-7080 Adapter for M (T-adapter) 1 q q
799-601-7090 Adapter for M 2 M2P q q q q
799-601-7340 Adapter for M 8 M8P q
799-601-7140 Adapter for S 8 S8P q q q q
799-601-7150 Adapter for S (White) 10 S10P q q q q
799-601-7160 Adapter for S (Blue) 12 S12P q q q
799-601-7170 Adapter for S (Blue) 16 S16P q q q q
799-601-7330 Adapter for S (White) 16 S16PW q
799-601-7350 Adapter for S (White) 12 S12PW q
799-601-7180 Adapter for AMP040 8 A8P q
799-601-7190 Adapter for AMP040 12 A12P q q
799-601-7210 Adapter for AMP040 16 A16P q q q q
799-601-7220 Adapter for AMP040 20 A20P q q q q
799-601-7230 Short connector for X 2 q q q q
799-601-7240 Case q q
799-601-7270 Case q
799-601-7510 Adapter for 070 10 07-10 q
799-601-7520 Adapter for 070 12 07-12 q
799-601-7530 Adapter for 070 14 07-14 q
799-601-7540 Adapter for 070 18 07-18 q
799-601-7550 Adapter for 070 20 07-20 q
799-601-7360 Adapter for relay 5 REL-5P q
799-601-7370 Adapter for relay 6 REL-6P q
799-601-7380 Adapter for JFC 2 q
799-601-9010 Adapter for DTM 2 DTM2 q q
799-601-9020 Adapter for DT 2 DT2 q q q q
799-601-9030 Adapter for DT 3 DT3 q q
799-601-9040 Adapter for DT 4 DT4 q q q q
799-601-9050 Adapter for DT 6 DT6 q q
799-601-9060 Adapter for DT (gray) 8 DT8GR q q
799-601-9070 Adapter for DT (black) 8 DT8B q q
799-601-9080 Adapter for DT (green) 8 DT8G q q
799-601-9090 Adapter for DT (Brown) 8 DT8BR q q
799-601-9110 Adapter for DT (gray) 12 DT12GR q q
PC360LC-10 40-101
40 Troubleshooting
T-adapter kit
Number of pins
Out of kit
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
799-601-9120 Adapter for DT (black) 12 DT12B q q

799-601-9130 Adapter for DT (green) 12 DT12G q q
799-601-9140 Adapter for DT (Brown) 12 DT12BR q q
799-601-9210 Adapter for HD30-18 8 D18-8 q q
799-601-9310 Plate for HD30 (24-pin) q q q
799-601-9320 T-box (for ECONO) 24 q q q
799-601-9330 Case q
799-601-9340 Case q
799-601-9350 Adapter for DRC 40 DRC-40 q
799-601-9360 Adapter for DRC 24 DRC-24 q
799-601-9410* Socket for engine (CRI-T2) 2 G q
Adapter for engine (CRI- q q
T2)
799-601-9420 Adapter for engine (CRI- 3 A3
T3) PFUEL
Oil pressure sensor
Socket for engine (CRI-T2) q q
799-601-9430* Socket for engine(CRI-T3) 2 P
PCV
799-601-9440* Socket for engine (CRI-T2) 3 1, 2, 3 q
795-799-5520* Socket for engine (HPI-T2) 2 S q
Socket for engine (HPI-T2) q q
795-799-5530* Socket for engine (CRI-T3) 2 C
Temperature sensor
Socket for engine (HPI-T2) q q
795-799-5540* Socket for engine(CRI-T3) 2 A
TIM
795-799-5460 Cable for engine (HPI-T2) 3 q
Adapter for engine (140-T3) q q
799-601-4110 4 ITT3N
PIM
799-601-4130 T3) NE, CAM 3 FCIN
799-601-4140 T3) 3 FCIG
Ambient pressure
40-102 PC360LC-10
40 Troubleshooting
T-adapter kit
Number of pins
Out of kit
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201

799-601-4150 T3) POIL 3 FCIB
799-601-4160 T3) 2 4160
Oil pressure switch
799-601-4180 T3) PEVA 3 4180
799-601-4190* 3 1, 2, 3L
Rail pressure
1, 2, 3,
799-601-4230* Air intake pressure/ 4
4C
temperature
799-601-4240* 3 1, 2, 3A
PAMB
799-601-4250* 3 1, 2, 3B
PIM
Socket for engine (CRI-T3) 1, 2, 3, q q
799-601-4330* 3
G G
799-601-4340* 2 2, PA
Pump actuator
Socket for engine (CRI-T3)
(95) 1, 2, 3,
799-601-4380* 4 q
Air intake pressure/ 4T
temperature
Adapter for controller q q
799-601-4260 (ENG) 4 DTP4
Adapter for controller q
799-601-4211 (ENG) 50 DRC50
Adapter for controller q
799-601-4220 (ENG) 60 DRC60
Socket for controller (95
799-601-4390* ENG) 60 q
799-601-4280* Box for controller (PUMP) 12- q

1
799-601-9720 Adapter for controller (HST) 16 HST16A q
799-601-9710 Adapter for controller (HST) 16 HST16B q
799-601-9730 Adapter for controller (HST) 26 HST26A q
2,
Multi-adapter for pins DT2
799-601-9890 3, q
to 4 and DTM2
4
*: Shows not T-adapter but socket.
PC360LC-10 40-103
40 Troubleshooting
T-adapter kit
Number of pins
Out of kit
799-A65-4600
799-601-4620 Adapter for controller (ENG-T4) 4 799-601-4620 q

KDPF delta pressure sensor
799T-601-4611 4 799T-601-4611 q
short connector
KDPF outlet pressure sensor
799T-601-4670 4 799T-601-4670 q
short connector
KDPF dummy temperature
799T-601-4680 4 799T-601-4680 q
sensor
40-104 PC360LC-10
40 Troubleshooting
Fuse location table (PC300-5530-04D-A-00-A)

Connection table of fuse box
a This connection table shows the fuse box and the devices which receive the power from the fuse box ( A
switched power supply is the power source which supplies power while the starting switch is in ON
position and a continuous power supply is the power source which supplies power while the starting
switch is in OFF and ON positions).
a When performing troubleshooting related to the electrical system, check the fuses and fusible links to see
if the power is supplied properly.
Type of
Fuse Fuse
power Fusible link Destination of power
No. capacity
supply
1 5A Working lamp relay, emergency switch
2 30 A Solenoid valve
3 5A PPC oil pressure lock solenoid
4 10 A Window washer, cigarette lighter
5 10 A Horn
6 5A Auto preheater
Fusible link
7 10 A Rotary lamp
Switched F04
8 10 A Radio, Speaker, L.H. knob switch
power (65 A)
9 20 A Working lamp, rearlamp
supply
10 20 A Air conditioner unit
11 10 A Headlamp
12 10 A Optianal power supply (1)
Optional power supply (2), 12 V power supply and
13 30 A
heated air suspension seat
Starting 14 5A Engine controller
switch ACC 15 5A Machine monitor, engine shutdown switch
16 10 A Radio backup, room lamp, system operating lamp
Machine monitor (continuous power supply), pump
Continuous Fusible link 17 20 A
controller
power F05
18 30 A Engine controller
supply (30 A)
19 5A Engine controller backup
20 10 A Optional power supply
Locations of fusible link
* The two fusible links (F04) and (F05) are accessible when the battery cover is lifted.
PC360LC-10 40-105
40 Troubleshooting
Location of fuse box and fuse number
40-106 PC360LC-10
40 Troubleshooting
Preparation of dummy temperature sensor (for KDOC and KDPF

temperature sensors) (HM300-A9J2-304-K-00-A)
• It is included in kit part number: 799-A65-4600.
• This dummy temperature sensor is used for KDPF related failure codes.
• Remove KDPF temperature sensor consolidating box which is installed to KDPF and install a dummy
temperature sensor instead. Dummy temperature sensor simulates the temperatures at KDOC inlet,
KDOC outlet, and KDPF outlet to approximately 560°C to 590°C by only setting the starting switch to ON
position in order to reduce stresses applied to engine and machine.
• Dummy temperature sensor
PC360LC-10 40-107
40 Troubleshooting
Preparation of short circuit electrical connector (for failure codes

[CA1883] and [CA3135]) (HM300-A9J2-304-K-01-A)
a The connector of KDPF differential pressure sensor is the same as that of KDPF outlet pressure sensor.
• It is included in the kit part number: 799-A65-4600.
• Short socket adapter for KDPF differential pressure sensor used for failure code [CA1883].
• Short socket adapter for KDPF outlet pressure sensor used for failure code [CA3135].
40-108 PC360LC-10
40 Troubleshooting
Precautions for KDPF (KCSF and KDOC) Cleaning and Replacement (D65-
A9H0-2A4-K-00-A)
1. Related information From service menu of machine monitor,

display the "Diagnostic Tests" screen, open
k Since KDPF and KDOC are heated to 500° "KDPF Memory Reset", and then perform
C or above, take care not to get burn "KDOC Cleaning" (reset after KDOC
injury. cleaning).
• Resetting after KDPF (KCSF) change
• Soot accumulation at KCSF inside the KDPF
From service menu of machine monitor,
is classified into 8 levels. The current soot
level can be checked on the machine
"KDPF Memory Reset", and then perform
monitor by selecting the "Diagnostic Test"
"KDPF Change" (resetting after KDPF
screen from the service menu, and then
change).
selecting the "Regeneration for Service"
screen. a When KCSF in KDPF is replaced, always
perform resetting procedures for KDPF
a If the soot accumulation reaches level 4 or 5,
cleaning and KDPF change, and then
failure code [CA2639] is displayed.
perform manual stationary regeneration from
a If the soot accumulation reaches level 6 or 7, "Regeneration for Service" to eliminate
failure code [CA1921] is displayed. moisture from KCSF.
a If the soot accumulation reaches level 8, • Resetting after KDOC change
failure code [CA1922] is displayed. From service menu of machine monitor,
• If the soot accumulation reaches level 8, the
"KDPF Memory Reset", and then perform
KDPF is completely clogged with soot, and
"KDOC Change" (reset after KDOC change).
inspection, cleaning, or replacement is
required. a When KDOC in KDPF is changed, resetting
• Manual stationary regeneration can be procedure for KDOC change must be
performed to burn away soot in the KCSF performed though manual stationary
when the soot accumulation is up to level 7. regeneration is not necessary.
2. When cleaning and replacing KCSF
a At soot accumulation levels 4 to 7, manual
stationary regeneration can also be 1) Regular cleaning at 4500H
performed from the user mode. 1] Check the soot accumulation level. If the
• Procedure of performing manual stationary level is not zero, repeat "Regeneration for
regeneration from Regeneration for Service Service" until the level returns to zero.
2] Stop the engine and wait until the
a When soot accumulation is at level 3 or lower, temperature of piping around the engine
the manual stationary regeneration can be cools down. Remove the KDPF, and then
performed only from "Regeneration for remove the KCSF.
Service". 3] Clean the KCSF by using an ash cleaner,
1) Start the engine. which is equipped at certain workshops.
2) Make sure that machine is in safe condition. (when the removed KCSF is cleaned and
3) From the service menu of the machine reused)
monitor, display the "Diagnostic Tests" 4] Install the cleaned KCSF to the machine.
screen, open "Regeneration for service", and (when the removed KCSF is cleaned and
then perform the "Manual Stationary reused)
Regeneration". 5] Install the replacement KCSF to the
machine (when the KCSF is replaced
a Time required for manual stationary
with a new one).
regeneration depends on the accumulated
6] Turn the starting switch to the ON
soot in KCSF, however, it is estimated as
position. From the KDPF reset screen,
follows.
perform resetting after KDPF cleaning.
• If soot accumulation is level 4: Approx. 40 7] Start the engine and run at low idle to
minutes to 1 hour warm up.
• If soot accumulation is level 5: Approx. 1 to 2 8] Perform regeneration for service.
hours 2) If cracks or damages are found during
• Resetting after KDPF (KCSF) cleaning inspection
PC360LC-10 40-109
40 Troubleshooting
1] Stop the engine and wait until the Case 1-4] From the KDPF reset screen, perform
temperature of piping around the engine resetting after KDPF change.
cools down. Remove the KDPF, and then Case 1-5] Start the engine and run at low idle to
remove the KCSF. warm up.
2] Install the replacement KCSF (new or Case 1-6] Perform Regeneration for Service.
reused) to the machine. (In this case, Regeneration for Service may
3] Turn the starting switch to the ON continue for about 2 hours, since it is set to
position. From the KDPF reset screen, terminate when the soot accumulation drops to
perform resetting after KDPF cleaning. 1.9 g/l.)
4] From the KDPF reset screen, perform Case 1-7] When Regeneration for Service is
resetting after KDPF change. completed, check that failure codes (CA1922,
5] Start the engine and run at low idle to CA1921, and CA2639) are not displayed.
warm up. <Case 2> When Regeneration for Service is
6] Perform regeneration for service. performed (KDPF removal unnecessary)
3) If Soot Level High Error 2 (CA1922) is
a If the following conditions are met, the total
displayed
soot sediment is not beyond the limit (9 g/l),
1] Stop the machine and check that failure but the differential pressure has increased
code (CA1922) is displayed on the due to clogging caused by uneven
machine monitor. accumulation of soot. In this case, actual
2] Check the abnormality record for failure regeneration will not result in abnormal
codes "CA2639: Manual Stationary burning. Regeneration for Service can be
Regeneration Request", "CA1921: KDPF performed safely without replacing the KCSF,
Soot Level High Error 1", and "CA1922: and the KCSF can be continuously used
KDPF Soot Level High Error 2"on the after the regeneration.
machine monitor.
• After checking that no sensor related failures
<Case 1> When KDPF is removed and KCSF is
are present, perform this work if any of the
replaced
following is met.
a If the following conditions are met, soot • Time between activation of "CA2639: Manual
accumulation is beyond the limit to burn Stationary Regeneration Request (L01)" and
away by regeneration. The KDPF must be "CA1921: KDPF Soot Level High Error 1
removed to change the KCSF. (L03)" < 360 sec. (KOMTRAX history) or <
• Time between activation of "CA2639: Manual 0.1 h (Abnormality record screen on monitor)
Stationary Regeneration Request (L01)" and • "Time between activation of "CA1921: KDPF
"CA1921: KDPF Soot Level High Error 1 Soot Level High Error 1 (L03)" and "CA1922:
(L03)" X 360 sec. (KOMTRAX history) or X KDPF Soot Level High Error 2 (L04)" <
0.1 h (Abnormality record screen on monitor) 360sec. (KOMTRAX history) or < 0.1 h
and (Abnormality record screen on monitor)
• Time between activation of "CA1921: KDPF [Contents of work]
Soot Level High Error 1 (L03)" and "CA1922: Case 2-1] Start the engine and run at low idle to
KDPF Soot Level High Error 2 (L04)" X360 warm up. From the KDPF reset screen, perform
sec. (KOMTRAX history) or X 0.1 h resetting after KDPF cleaning.
(Abnormality record screen on monitor) Case 2-2] Perform Regeneration for Service.
[Contents of work] (In this case, Regeneration for Service may
Case 1-1] Stop the engine and wait until the continue for about 2 hours, since it is set to
temperature of piping around the engine cools terminate when the soot accumulation drops to
down, then remove KCSF. 1.9 g/l.)
Case 1-2] Install the replacement KCSF (new or Case 2-3] When Regeneration for Service is
reused). completed, check that failure codes (CA1922,
Case 1-3] Turn the starting switch to the ON CA1921, and CA2639) are not displayed.
position. From the KDPF reset screen, perform 3. When cleaning and replacing KDOC
resetting after KDPF cleaning. 1) If cracks or damages are found during
inspection
a When resetting after KDPF cleaning is
performed, changes in ( ) are reflected. 1] If cracks or damages are found in the
(Soot accumulation amount: 9 g/lo8.1 g/l; KDOC, replace it with a new one.
Action level: L04oL03; Failure code: 2] From the KDPF reset screen, perform
CA1922oCA1921) resetting after KDOC change.
40-110 PC360LC-10
40 Troubleshooting
2) When Regeneration Ineffective (CA1691) is

displayed
1] Stop the machine and check that failure
code (CA1691) is displayed on the
machine monitor.
(CA2637 may be displayed at the same
time.)
2] Check the exhaust gas color.
3] With CA1691 displayed, perform
Regeneration for Service for 40 minutes.
(Since this is done for drying the KDOC,
fuel is not injected during the
regeneration)
4] Stop the engine and wait until the
temperature of piping around the engine
cools down. Remove the KDOC and
check it for cracks or damages.
<Case 1> If cracks or damages are found in
KDOC
Case 1-1] Replace KDOC with a new one.
Case 1-2] From the KDPF reset screen,
perform resetting after KDOC change.
<Case 2> If cracks or damages are not found
in KDOC
Case 2-1] Clean KDOC and reinstall it.
Case 2-2] From the KDPF reset screen,
perform resetting after KDOC cleaning.
Case 2-3] Perform Regeneration for Service
twice for 40 minutes each. (Fuel is injected
during regeneration)
*When performing Regeneration for Service
several times, stop the engine each time
before repeating the regeneration.
Case 2-4] If failure code "CA2637: KDOC
Face Plugging" is displayed after
Regeneration for Service is completed, the
catalyst performance of KDOC is
deteriorated. Replace KDOC with a new one.
PC360LC-10 40-111
40 Troubleshooting
Failure codes table (PC300-5520-441-A-00-A)

Compo-
Failure Action Category
Failure (Displayed on screen) nent in Remarks
code level history
charge
Failure code [879AKA] A/C Inner Sensor Electrical See Chapter
879AKA MON -
Open Circuit(PAGE 40-121) system 80, Appendix
Failure code [879AKB] A/C Inner Sensor Electrical See Chapter
879AKB MON -
Short Circuit(PAGE 40-122) system 80, Appendix
Failure code [879BKA] A/C Outer Sensor Electrical See Chapter
879BKA MON -
Failure code [879BKB] A/C Outer Sensor Electrical See Chapter
879BKB MON -
Failure code [879CKA] Ventilating Sensor Electrical See Chapter
879CKA MON -
Failure code [879CKB] Ventilating Sensor Electrical See Chapter
879CKB MON -
Failure code [879DKZ] Sunlight Sensor Open Electrical See Chapter
879DKZ MON -
Or Short Circuit(PAGE 40-127) system 80, Appendix
Failure code [879EMC] Ventilation Damper Electrical See Chapter
879EMC Abnormality(PAGE 40-128) MON L01 system 80, Appendix
Failure code [879FMC] Air Mix Damper Electrical See Chapter
879FMC Abnormality(PAGE 40-129) MON L01 system 80, Appendix
Failure code [879GKX] Refrigerant Electrical See Chapter
879GKX Abnormality(PAGE 40-130) MON L01 system 80, Appendix
Failure code [989L00] Engine Controller Lock Electrical
989L00 MON -
Caution 1(PAGE 40-131) system
Failure code [989M00] Engine Controller Lock Electrical
989M00 MON -
Failure code [989N00] Engine Controller Lock Electrical
989N00 MON -
Failure code [A1U0N3] HC Desorb Request 1 PUMP/ Electrical
A1U0N3 (PAGE 40-134) L01 system
ENG
Failure code [A1U0N4] HC Desorb Request 2 PUMP/ Electrical
A1U0N4 (PAGE 40-136) L03 system
ENG
Failure code [AA10NX] Air Cleaner Clogging Mechanical
AA10NX (PAGE 40-138) MON L01 system
Failure code [AB00KE] Charge Voltage Low Mechanical
AB00KE (PAGE 40-140) MON L03 system
Failure code [B@BAZG] Eng Oil Press Low Mechanical
B@BAZG ENG L03
(PAGE 40-142) system
Failure code [B@BAZK] Eng Oil Level Low Mechanical
B@BAZK MON L01
Failure code [B@BCNS] Eng Water Overheat Mechanical
B@BCNS ENG L02
Failure code [B@BCZK] Eng Water Level Mechanical
B@BCZK MON L01
Low(PAGE 40-145) system
Failure code [B@HANS] Hyd Oil Overheat Mechanical
B@HANS PUMP L02
Failure code [CA115] Eng Ne and Bkup Electrical
CA115 Speed Sens Error(PAGE 40-148) ENG L04 system
Failure code [CA122] Chg Air Press Sensor Electrical
CA122 High Error(PAGE 40-149) ENG L03 system
CA123 Low Error(PAGE 40-151) ENG L03 system
Failure code [CA131] Throttle Sensor High Electrical
CA131 Error(PAGE 40-153) ENG L03 system
Failure code [CA132] Throttle Sensor Low Electrical
40-112 PC360LC-10
40 Troubleshooting
Compo-
code level history
charge
Failure code [CA144] Coolant Temp Sens Electrical
Failure code [CA145] Coolant Temp Sens Electrical
Failure code [CA153] Chg Air Temp Sensor Electrical
Failure code [CA154] Chg Air Temp Sensor Electrical
Failure code [CA187] Sensor 2 Supply Volt Electrical
Failure code [CA221] Ambient Press Sensor Electrical
Failure code [CA222] Ambient Press Sensor Electrical
Failure code [CA234] Eng Overspeed(PAGE Mechanical
CA234 40-172) ENG L02 system
Failure code [CA238] Ne Speed Sensor Electrical
CA238 Supply Volt Error(PAGE 40-173) ENG L01 system
Failure code [CA239] Ne Speed Sens Supply Electrical
CA239 Volt High Error(PAGE 40-174) ENG L01 system
Failure code [CA271] IMV/PCV1 Short Error Electrical
CA271 (PAGE 40-175) ENG L03 system
Failure code [CA272] IMV/PCV1 Open Error Electrical
Failure code [CA281] Pump Press Balance Electrical
Failure code [CA295] Ambient Pressure Electrical
CA295 Sensor In Range Error(PAGE 40-180) ENG L03 system
Failure code [CA322] Inj #1(L#1) Open/Short Electrical
Failure code [CA343] ECM Critical Internal Electrical
CA343 Failure(PAGE 40-193) ENG L04 system
Failure code [CA351] Injectors Drive Circuit Electrical
Failure code [CA356] Mass Air Flow Sensor Electrical
PC360LC-10 40-113
40 Troubleshooting
Compo-
code level history
charge
Failure code [CA428] Water in Fuel Sensor Electrical
Failure code [CA429] Water in Fuel Sensor Electrical
Failure code [CA435] Eng Oil Press Sw Error Electrical
Failure code [CA441] Battery Voltage Low Electrical
Failure code [CA442] Battery Voltage High Electrical
Failure code [CA449] Rail Press Very High Electrical
Failure code [CA451] Rail Press Sensor High Electrical
Failure code [CA452] Rail Press Sensor Low Electrical
Failure code [CA488] Chg Air Temp High Electrical
CA488 Torque Derate(PAGE 40-216) ENG L03 system
Failure code [CA515] Rail Press Sens Sup Electrical
CA515 Volt High Error(PAGE 40-217) ENG L03 system
Failure code [CA516] Rail Press Sens Sup Electrical
CA516 Volt Low Error(PAGE 40-219) ENG L03 system
Failure code [CA553] Rail Press High Error Electrical
Failure code [CA555] Crankcase Press High Electrical
CA555 Error 2(PAGE 40-222) ENG L01 system
Failure code [CA556] Crankcase Press High Electrical
Failure code [CA559] Rail Pump Press Low Electrical
Failure code [CA595] Turbo Speed High Error Electrical
CA595 2(PAGE 40-228) ENG L01 system
Failure code [CA687] Turbo Speed Low Error Electrical
Failure code [CA689] Eng Ne Speed Sensor Electrical
Failure code [CA691] Intake Air Temp Sens Electrical
Failure code [CA692] Intake Air Temp Sens Electrical
Failure code [CA697] ECM Internal Temp Electrical
CA697 Sensor High Error(PAGE 40-239) ENG L01 system
Failure code [CA698] ECM Int Temp Sensor Electrical
Failure code [CA731] Eng Bkup Speed Sens Electrical
CA731 Phase Error(PAGE 40-241) ENG L03 system
Failure code [CA778] Eng Bkup Speed Electrical
CA778 Sensor Error(PAGE 40-243) ENG L03 system
Failure code [CA1117] Persistent Data Lost Electrical
Failure code [CA1664] KDOC Malfunction Electrical
Failure code [CA1691] Regeneration Electrical
CA1691 Ineffective(PAGE 40-251) ENG L03 system
40-114 PC360LC-10
40 Troubleshooting
Compo-
code level history
charge
Failure code [CA1695] Sens 5 Supply Volt Electrical
Failure code [CA1696] Sens 5 Supply Volt Electrical
Failure code [CA1843] Crankcase Press Electrical
CA1843 Sens High Error(PAGE 40-257) ENG L01 system
CA1844 Sens Low Error(PAGE 40-259) ENG L01 system
Failure code [CA1879] KDPF Delta P Sensor Electrical
Failure code [CA1881] KDPF Delta P Sensor Electrical
Failure code [CA1883] KDPF Delta P Sens In Electrical
CA1883 Range Error(PAGE 40-265) ENG L03 system
Failure code [CA1921] KDPF Soot Load High Electrical
Failure code [CA1922] KDPF Soot Load High Electrical
CA1942 Sens In Range Error(PAGE 40-276) ENG L01 system
Failure code [CA1993] KDPF Delta Pressure Electrical
Failure code [CA2185] Throt Sens Sup Volt Electrical
Failure code [CA2186] Throt Sens Sup Volt Electrical
Failure code [CA2249] Rail Press Very Low Electrical
Failure code [CA2265] Fuel Feed Pump Open Electrical
Failure code [CA2266] Fuel Feed Pump Short Electrical
Failure code [CA2271] EGR Valve Pos Sens Electrical
Failure code [CA2272] EGR Valve Pos Sens Electrical
Failure code [CA2288] Turbo Speed High Electrical
Failure code [CA2311] IMV Solenoid Error Electrical
Failure code [CA2349] EGR Valve Solenoid Electrical
CA2349 Open Error(PAGE 40-296) ENG L03 system
Failure code [CA2353] EGR Valve Solenoid Electrical
CA2353 Short Error(PAGE 40-298) ENG L03 system
Failure code [CA2357] EGR Valve Servo Electrical
Failure code [CA2373] Exhaust Manifold Electrical
CA2373 Press Sens High error(PAGE 40-301) ENG L03 system
Failure code [CA2374] Exhaust Manifold Electrical
CA2374 Press Sens Low error(PAGE 40-303) ENG L03 system
Failure code [CA2375] EGR Orifice Temp Electrical
PC360LC-10 40-115
40 Troubleshooting
Compo-
code level history
charge
Failure code [CA2381] KVGT Pos Sens High Electrical
Failure code [CA2382] KVGT Pos Sens Low Electrical
Failure code [CA2383] KVGT Solenoid Open Electrical
Failure code [CA2386] KVGT Solenoid Short Electrical
Failure code [CA2387] KVGT Servo Error Electrical
Failure code [CA2554] Exh Manifold Press Electrical
Failure code [CA2555] Grid Htr Relay Open Electrical
CA2555 Circuit Error(PAGE 40-320) ENG L01 system
Failure code [CA2556] Grid Htr Relay Short Electrical
CA2556 Circuit Error(PAGE 40-322) ENG L01 system
Failure code [CA2637] KDOC Face Plugging Electrical
Failure code [CA2639] Manual Stationary Electrical
CA2639 Regeneration Request(PAGE 40-326) ENG L01 system
CA2961 High Error 1(PAGE 40-329) ENG L03 system
CA2973 In Range Error(PAGE 40-330) ENG L03 system
Failure code [CA3133] KDPF Outlet Press Electrical
Failure code [CA3251] KDOC Inlet Temp High Electrical
Failure code [CA3253] KDOC Temp Error - Electrical
CA3253 Non Regeneration(PAGE 40-342) ENG L03 system
Failure code [CA3254] KDOC Outlet Temp Electrical
Failure code [CA3255] KDPF Temp Error - Electrical
CA3255 Non Regeneration(PAGE 40-348) ENG L03 system
Failure code [CA3256] KDPF Outlet Temp Electrical
Failure code [CA3313] KDOC Inlet Temp Electrical
CA3313 Sensor Low Error(PAGE 40-360) ENG L03 system
40-116 PC360LC-10
40 Troubleshooting
Compo-
code level history
charge
CA3419 Sup Volt High Error(PAGE 40-393) ENG L03 system
CA3421 Sup Volt Low Error(PAGE 40-395) ENG L03 system
Failure code [CA3741] Rail Press Valve Trip Electrical
Failure code [CA3741] Rail Press Valve Trip Electrical
D110KB Error(PAGE ) PUMP L01 system
Failure code [D19JKZ] Personal Code Relay Electrical
D19JKZ Abnormality(PAGE 40-400) MON L03 system
Failure code [D811MC] KOMTRAX Error KOM- Electrical
D811MC -
(PAGE 40-403) TRAX system
Failure code [D862KA] GPS Antenna Open KOM- Electrical
D862KA -
Circuit(PAGE 40-404) TRAX system
Failure code [D8ALKA] System Operating
KOM- Electrical
D8ALKA Lamp Disconnection (KOMTRAX)(PAGE 40- -
TRAX system
405)
Failure code [D8ALKB] System Operating
KOM- Electrical
D8ALKB Lamp Short Circuit (KOMTRAX)(PAGE 40- -
TRAX system
407)
Failure code [D8AQKR] CAN2 Discon Electrical
D8AQKR MON -
(KOMTRAX)(PAGE 40-408) system
Failure code [DA20MC] Pump Controller Electrical
DA20MC PUMP -
Malfunction(PAGE 40-409) system
Failure code [DA22KK] Pump Solenoid Power Electrical
DA22KK Low Error(PAGE 40-410) PUMP L03 system
Failure code [DA25KP] 5V Sensor1 Power Electrical
DA25KP PUMP -
Abnormality(PAGE 40-412) system
Failure code [DA29KQ] Model Selection Electrical
DA29KQ Abnormality(PAGE 40-415) PUMP L01 system
Failure code [DA2LKA] System Operating
Electrical
DA2LKA Lamp Disconnection (Pump Con)(PAGE 40- PUMP -
system
417)
Failure code [DA2LKB] System Operating
Electrical
DA2LKB Lamp Short Circuit (Pump Con)(PAGE 40- PUMP -
system
419)
Failure code [DA2QKR] CAN2 Discon ( Pump Electrical
DA2QKR Con)(PAGE 40-420) MON L03 system
Failure code [DA2RKR] CAN1 Discon ( Pump Electrical
DA2RKR Con)(PAGE 40-423) MON L04 system
Failure code [DAF0MB] Monitor ROM Electrical
DAF0MB MON -
Abnormality(PAGE 40-424) system
Failure code [DAF0MC] Monitor Error(PAGE Electrical
DAF0MC MON -
40-425) system
Failure code [DAF8KB] Camera Power Electrical
DAF8KB Supply Short Circuit(PAGE 40-426) MON L03 system
Failure code [DAF9KQ] Model Selection Electrical
DAF9KQ Abnormality(PAGE 40-428) MON L03 system
PC360LC-10 40-117
40 Troubleshooting
Compo-
code level history
charge
Failure code [DAFGMC] GPS Module Error KOM- Electrical
DAFGMC (PAGE 40-429) -
TRAX system
Failure code [DAFLKA] Operating Lamp Open Electrical
DAFLKA Circuit(Monitor)(PAGE 40-430) MON -
system
Failure code [DAFLKB] System Operating Electrical
DAFLKB Lamp Short Circuit (Monitor)(PAGE 40-432) MON -
system
Failure code [DAFQKR] CAN2 Discon KOM- Electrical
DAFQKR (Monitor)(PAGE 40-433) -
TRAX system
Failure code [DAZ9KQ] AC Model Selection Electrical
DAZ9KQ Abnormality(PAGE 40-434) MON -
system
Failure code [DAZQKR] CAN2 Discon (AC) Electrical
DAZQKR (PAGE 40-435) MON L01 system
Failure code [DB2QKR] CAN2 Discon Electrical
DB2QKR (Engine Con)(PAGE 40-440) MON L03 system
Failure code [DB2RKR] CAN1 Discon Electrical
DB2RKR (Engine Con)(PAGE 40-445) MON L04 system
Failure code [DGH2KB] Hyd Oil Sensor Short Electrical
DGH2KB Circuit(PAGE 40-449) PUMP L01 system
Failure code [DHA4KA] Air Cleaner Clogging Electrical
DHA4KA Sensor Open Circuit(PAGE 40-451) MON L01 system
Failure code [DHPAMA] Pump Press Sensor Electrical
DHPAMA Abnormality(PAGE 40-453) PUMP L01 system
Failure code [DHPBMA] R Pump Press Electrical
DHPBMA Sensor Abnormality(PAGE 40-456) PUMP L01 system
Failure code [DHS3MA] Arm IN PPC Sen. Electrical
DHS3MA Abnormality(PAGE 40-459) PUMP L01 system
Failure code [DHS4MA] Bucket CURL PPC Electrical
DHS4MA Press Sensor Abnormality(PAGE 40-461) PUMP L01 system
Failure code [DHS8MA] Boom RAISE PPC Electrical
DHS8MA Press Sensor Abnormality(PAGE 40-464) PUMP L01 system
Failure code [DHS9MA] Boom LOWER Press Electrical
DHS9MA Sensor Abnormality(PAGE 40-467) PUMP L01 system
Failure code [DHSAMA] Swing RH PPC Electrical
DHSAMA Press Sensor Abnomality(PAGE 40-470) PUMP L01 system
Failure code [DHSBMA] Swing LH PPC Press Electrical
DHSBMA Sensor Abnomality(PAGE 40-473) PUMP L01 system
Failure code [DHSCMA] Arm OUT PPC Press Electrical
DHSCMA Sensor Abnormality(PAGE 40-476) PUMP L01 system
Failure code [DHSDMA] Bucket Dump PPC Electrical
DHSDMA Press Sensor Abnormality(PAGE 40-479) PUMP L01 system
Failure code [DHSFMA] Travel FW L PPC Electrical
DHSFMA Press Sensor Abnormality(PAGE 40-482) PUMP L01 system
Failure code [DHSGMA] Travel FW R PPC Electrical
DHSGMA Press Sensor Abnormality(PAGE 40-485) PUMP L01 system
Failure code [DHSHMA] Travel BW L PPC Electrical
DHSHMA Press Sensor Abnormality(PAGE 40-488) PUMP L01 system
Failure code [DHSJMA] Travel BW R PPC Electrical
DHSJMA Press Sensor Abnormality(PAGE 40-491) PUMP L01 system
Failure code [DKR0MA] F pump S/P sensor Electrical
DKR0MA Abnormality(PAGE 40-494) PUMP L01 system
Failure code [DKR1MA] R pump S/P sensor Electrical
DKR1MA Abnormality(PAGE 40-496) PUMP L01 system
Failure code [DR21KX] Camera 2 Picture Electrical
DR21KX Rev. Drive Abnormality(PAGE 40-498) PUMP L01 system
40-118 PC360LC-10
40 Troubleshooting
Compo-
code level history
charge
Failure code [DR31KX] Camera 3 Picture Electrical
DR31KX Rev. Drive Abnormality(PAGE 40-500) PUMP L01 system
Failure code [DV20KB] Travel Alarm Short Electrical
DV20KB Circuit(PAGE 40-502) PUMP L01 system
Failure code [DW43KA] Travel Speed Sol Electrical
DW43KA Open Circuit(PAGE 40-504) PUMP L01 system
Failure code [DW43KB] Travel Speed Sol Electrical
DW43KB Short Circuit(PAGE 40-506) PUMP L01 system
Failure code [DW45KA] swing holding brake Electrical
DW45KA Sol Open Circuit(PAGE 40-508) PUMP L03 system
Failure code [DW45KB] Swing Brake Sol Electrical
Failure code [DW91KA] Travel Junction Sol Electrical
DW91KA Open Circuit(PAGE 40-514) PUMP L01 system
Failure code [DW91KB] Travel Junction Sol Electrical
Failure code [DWA2KA] Attachment Sol Open Electrical
DWA2KA Circuit(PAGE 40-518) PUMP L03 system
Failure code [DWA2KB] Attachment Sol Short Electrical
DWA2KB Circuit(PAGE 40-520) PUMP L03 system
Failure code [DWK0KA] 2-stage Relief Sol Electrical
DWK0KA Open Circuit(PAGE 40-522) PUMP L01 system
Failure code [DWK0KB] 2-stage Relief Sol Electrical
DWK0KB Short Circuit(PAGE 40-524) PUMP L01 system
Failure code [DWK2KA] Variable Back Electrical
DWK2KA Pressure Sol Open Circuit(PAGE 40-526) PUMP L01 system
Failure code [DWK2KB] Variable Back Electrical
DWK2KB Pressure Sol Short Circuit(PAGE 40-528) PUMP L01 system
Failure code [DWK8KA] Swing C/O Solenoid Electrical
DWK8KA Open Circuit(PAGE 40-530) PUMP L01 system
Failure code [DWK8KB] Swing C/O Solenoid Electrical
DWK8KB Short Circuit(PAGE 40-532) PUMP L01 system
Failure code [DXA8KA] PC-EPC (F) Sol Open Electrical
DXA8KA Circuit(PAGE 40-534) PUMP L03 system
Failure code [DXA8KB] PC-EPC (F) Sol Short Electrical
DXA8KB Circuit(PAGE 40-536) PUMP L03 system
Failure code [DXA9KA] PC-EPC (R) Sol Electrical
DXA9KA Open Circuit(PAGE 40-538) PUMP L03 system
Failure code [DXA9KB] PC-EPC (R) Sol Short Electrical
DXA9KB Circuit(PAGE 40-540) PUMP L03 system
Failure code [DXE0KA] LS-EPC Sol Open Electrical
DXE0KA Circuit(PAGE 40-542) PUMP L01 system
Failure code [DXE0KB] LS-EPC Sol Short Electrical
DXE0KB Circuit(PAGE 40-544) PUMP L01 system
Failure code [DXE4KA] Service Current EPC Electrical
DXE4KA Disc.(PAGE 40-546) PUMP -
system
Failure code [DXE4KB] Service Current EPC Electrical
DXE4KB S/C(PAGE 40-547) PUMP -
system
Failure code [DXE5KA] Merge-divider Main Electrical
DXE5KA Sol Open Circuit(PAGE 40-548) PUMP L01 system
Failure code [DXE5KB] Merge-divider Main Electrical
DXE5KB Sol Short Circuit(PAGE 40-550) PUMP L01 system
Failure code [DXE6KA] Merge-divider LS Sol Electrical
DXE6KA Open Circuit(PAGE 40-552) PUMP L01 system
PC360LC-10 40-119
40 Troubleshooting
Compo-
code level history
charge
Failure code [DXE6KB] Merge-divider LS Sol Electrical
DXE6KB Short Circuit(PAGE 40-554) PUMP L01 system
Failure code [DY20KA] Wiper Working Electrical
DY20KA Abnormality(PAGE 40-556) PUMP -
system
Failure code [DY20MA] Wiper Parking Electrical
DY20MA Abnormality(PAGE 40-558) PUMP -
system
Failure code [DY2CKB] Washer Drive Short Electrical
DY2CKB Circuit(PAGE 40-560) PUMP -
system
Failure code [DY2DKB] Wiper Drive (For) Electrical
DY2DKB Short(PAGE 40-562) PUMP -
system
Failure code [DY2EKB] Wiper Drive (Rev) Electrical
DY2EKB Short(PAGE 40-564) PUMP -
system
40-120 PC360LC-10
40 Troubleshooting
Troubleshooting by failure code (Display of code)
Troubleshooting by failure code (Display of code) (ALL-3840-001-A-00-A)
Failure code [879AKA] A/C Inner Sensor Open Circuit (PC400-879AKA-441-A-Z0-A)
See chapter 80 Appendix "Failure code [879AKA] Air Conditioner Inner Sensor Open Circuit"
a Since the inner air temperature sensor connector cannot be disconnected with the sensor installed on the
machine, the air conditioner controller or air conditioner unit must be replaced.
PC360LC-10 40-121
40 Troubleshooting
Failure code [879AKB] A/C Inner Sensor Short Circuit (PC400-879AKB-441-A-Z0-A)
See chapter 80 Appendix "Failure code [879AKB] Air Conditioner Inner Sensor Short Circuit" .
a Since the inner air temperature sensor connector cannot be disconnected with the sensor installed on the
machine, the air conditioner controller or air conditioner unit must be replaced.
40-122 PC360LC-10
40 Troubleshooting
Failure code [879BKA] A/C Outer Sensor Open Circuit (PC400-879BKA-441-A-Z0-A)
See chapter 80 Appendix "Failure code [879BKA] Air Conditioner Outer Sensor Open Circuit" .
PC360LC-10 40-123
40 Troubleshooting
Failure code [879BKB] A/C Outer Sensor Short Circuit (PC400-879BKB-441-A-Z0-A)
See chapter 80 Appendix "Failure code [879BKB] Air Conditioner Outer Sensor Short Circuit" .
40-124 PC360LC-10
40 Troubleshooting
Failure code [879CKA] Ventilating Sensor Open Circuit (PC400-879CKA-441-A-Z0-A)
See chapter 80 Appendix "Failure code [879CKA] Ventilating Sensor Open Circuit"
a Since the ventilating sensor (evaporator temperature sensor) cannot be disconnected with the sensor
installed on the machine, the air conditioner controller or air conditioner unit must be replaced.
PC360LC-10 40-125
40 Troubleshooting
Failure code [879CKB] Ventilating Sensor Short Circuit (PC400-879CKB-441-A-Z0-A)
See chapter 80 Appendix "Failure code [879CKB] Ventilating Sensor Short Circuit"
a Since the ventilating sensor (evaporator temperature sensor) cannot be disconnected with the sensor
installed on the machine, the air conditioner controller or air conditioner unit must be replaced.
40-126 PC360LC-10
40 Troubleshooting
Failure code [879DKZ] Sunlight Sensor Open Or Short Circuit (PC400-879DKZ-441-

A-Z0-A)
See chapter 80 Appendix "Failure code [879DKZ] Sunlight Sensor Open or Short Circuit".
PC360LC-10 40-127
40 Troubleshooting
Failure code [879EMC] Ventilation Damper Abnormality (PC400-879EMC-441-A-Z0-A)
See chapter 80 Appendix "Failure code [879EMC] Ventilation Damper Abnormality".

a Since the vent select servo motor cannot be disconnected on the machine, the air conditioner controller or
air conditioner unit must be replaced.
40-128 PC360LC-10
40 Troubleshooting
Failure code [879FMC] Air Mix Damper Abnormality (PC400-879FMC-441-A-Z0-A)
See chapter 80 Appendix "Failure code [879FMC] Air Mix Damper Abnormality".
a Since the air mix servo motor connector cannot be disconnected on the machine, the air conditioner
controller or air conditioner unit must be replaced.
PC360LC-10 40-129
40 Troubleshooting
Failure code [879GKX] Refrigerant Abnormality (PC400-879GKX-441-A-Z0-A)
See chapter 80 Appendix "Failure code [879GKX] Refrigerant Abnormality".
40-130 PC360LC-10
40 Troubleshooting
Failure code [989L00] Engine Controller Lock Caution 1 (PC400-989L00-400-A-Z0-A)
Action level Failure code Engine Controller Lock Caution 1

Failure
– 989L00 (Machine monitor system)
Detail of • Engine controller lock up is detected (Factor 1).
failure
Action of • None in particular
machine • If cause of failure disappears, machine becomes normal by itself.
monitor
Problem on • Engine cannot be started.
machine
• If this failure code is generated after machine monitor is replaced, user password must be
Related changed to one before replacement.
information • Method of reproducing failure code: Turn starting switch to ON position.
Replacement of machine This problem may be caused by replacement of machine monitor.
1
monitor
PC360LC-10 40-131
40 Troubleshooting
Failure code [989M00] Engine Controller Lock Caution 2 (PC400-989M00-400-A-Z0-A)

Failure
– 989M00 (Machine monitor system)
failure
monitor
Problem on • Engine cannot be started.
machine
• If this failure code is generated after machine monitor is replaced, user password must be
Related changed to one before replacement.
Replacement of machine This problem may be caused by replacement of machine monitor.
1
monitor
If this failure code is displayed while machine monitor is not replaced,
2 Defective machine monitor machine monitor may be defective. (Since this is an internal defect,
troubleshooting cannot be performed.)
40-132 PC360LC-10
40 Troubleshooting
Failure code [989N00] Engine Controller Lock Caution 3 (PC400-989N00-400-A-Z0-A)

Failure
– 989N00 (Machine monitor system)
failure
Action of • Tries automatic recovery.
monitor
Problem on
machine
Related • Method of reproducing failure code: Failure code cannot be reproduced since machine
information recovers when cause of failure disappears.
If this failure code is generated repeatedly, engine controller may be
1 Defective engine controller defective. (Since this is an internal defect, troubleshooting cannot be
performed.)
PC360LC-10 40-133
40 Troubleshooting
Failure code [A1U0N3] HC Desorb Request 1 (PC400-A1U0N3-400-A-Z0-A)
Action level Failure code HC Desorb Request 1

Failure
L01 A1U0N3 (Engine controller system)
Detail of • Unburned fuel remains in KDPF because engine has been run at low idle or with low load
failure for a long time.
Action of • Requests manual stationary regeneration (fuel drying) to operator.
controller a Or, informs that manual stationary regeneration (fuel drying) is in progress.
Problem on Machine comes into same state as that of automatic regeneration.
machine (When machine is in safe condition, engine speed is limited to approximately 1,000 rpm.
k Since KDPF and KDOC are heated to 500°C or above, take care not to get burn
injury.
• Signal voltage from KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47301 (V))
• Temperature sensed by KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47300 (°C))
• Signal voltage from KDOC outlet temperature sensor can be checked with monitoring
• Temperature sensed by KDOC outlet temperature sensor can be checked with monitoring
• Signal voltage from KDPF outlet temperature sensor can be checked with monitoring
• Temperature sensed by KDPF outlet temperature sensor can be checked with monitoring
• KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet temperature when
Related engine is at idle (KDPF regeneration is not executed) are approximately 100 to 250°C,
information and difference between these temperatures is approximately 10°C. (KDOC inlet
temperature > KDOC outlet temperature > KDPF outlet temperature)
• When active regeneration (manual stationery regeneration) is performed due to guidance
of monitor displaying failure code [A1U0N3] or [A1U0N4], fuel dosing is disabled.
Accordingly, each temperature of KDOC inlet, KDOC outlet, and KDPF outlet reaches to
approximately 250 to 400 °C.
• When active regeneration (manual stationary regeneration) except above is in progress,
KDOC inlet temperature is approximately 250 to 400 °C, and KDOC outlet temperature
and KDPF outlet temperature are approximately 450 to 550 °C.
• If KDOC inlet temperature differs noticeably from KDOC outlet temperature when KDPF is
completely cool or engine running at idle (non-regeneration), replace KDOC inlet
temperature sensor or KDOC outlet temperature sensor, whichever is suspected to be
abnormal, judging by KDPF outlet temperature reading.
• KDOC inlet temperature sensor connecter label "TEMP1" is indicated on KDPF
temperature sensor consolidating box in black embossed letters (same for KDOC outlet
temperature sensor connector label "TEMP2" and KDPF outlet sensor connector label
"TEMP3").
• Method of reproducing failure code: Turn starting switch to ON position.
Performing manual stationary 1. Perform manual stationary regeneration by following instructions of
regeneration monitor.
1
If this failure code is cleared after regeneration is performed, repair is
(to dry KDPF)
complete.
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General
information on troubleshooting", and check it.
2 Defective harness connector 2. Turn starting switch to ON position.
If this failure code disappears, harness connector is defective.
a If this failure code appears, perform following checks.
Defective KDOC inlet If failure code [CA3313], [CA3314], or [CA3315] is also displayed,
3 temperature sensor perform troubleshooting for [CA3313], [CA3314], or [CA3315].
40-134 PC360LC-10
40 Troubleshooting

1. Turn starting switch to ON position.
4 Defective engine controller If this failure code appears and no failure is found by above checks,
engine controller is defective. (Since this is an internal defect,
a Turn starting switch to ON position and check that this failure code is not displayed.
PC360LC-10 40-135
40 Troubleshooting
Failure code [A1U0N4] HC Desorb Request 2 (PC400-A1U0N4-400-A-Z0-A)
Action level Failure code HC Desorb Request 2

Failure
L03 A1U0N4 (Engine controller system)
Detail of • Unburned fuel remains in KCSF because engine has been run at low idle or low load for a
failure long time.
Action of Requests manual stationary regeneration (fuel drying) to operator.
controller Or, informs that manual stationary regeneration (fuel drying) is in progress.
Problem on Machine comes into same state as that of automatic regeneration.
machine (When machine is in safe condition, engine speed is limited to approximately 1,000 rpm.)
k Since the temperature of the KDPF and KDOC will become higher than 500 °C , take
care not to get burn injury.
function. (Code: 47301(V))
function. (Code: 47300 (°C ))
• KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet temperature with
engine running at idle (without regenerating) are all approximately 100 to 250 °C and
temperature differences among them are approximately 10 °C (KDOC inlet
Related temperature>KDOC outlet temperature>KDPF outlet temperature).
information • When manual stationary regeneration is performed as an action taken for A1U0N3 or
A1U0N4, dosing fuel is not injected. Therefore, KDOC inlet, KDOC outlet, and KDPF
outlet temperatures will be around 250 to 400 °C .
• In other cases than the above, when active regeneration (manual stationary regeneration)
is in progress, the KDOC inlet temperature will be approximately 250 to 400 °C , and the
KDOC outlet temperature and KDPF outlet temperature will both be approximately 450 to
550 °C .
• It takes approximately 40 minutes to perform active regeneration (manual stationary
regeneration).
• If there is a significant difference between the KDOC inlet temperature and KDOC outlet
temperature when the KDPF is completely cool or engine running at idle (not
regenerating), replace the KDOC inlet temperature sensor or the KDOC outlet
temperature sensor, whichever is suspected to be abnormal, judging by the KDPF outlet
temperature reading.
• KDOC inlet temperature sensor connecter label "TEMP1" is indicated on KDPF
temperature sensor consolidating box in black embossed letters (same for KDOC outlet
temperature sensor connector label "TEMP2" and KDPF outlet sensor connector label
"TEMP3").
1. Perform manual stationary regeneration by following the instructions
Performing manual stationary on the monitor.
1
regeneration (to dry KCSF) If this failure code is cleared after regeneration is performed, repair is
complete.
Defective wiring harness information on troubleshooting", and check it.
2 2. Turn starting switch to ON position.
connector
If this failure code does not appear, harness connector is defective.
a If this failure code appears, perform the following.
40-136 PC360LC-10
40 Troubleshooting

Defective KDOC inlet If failure code [CA3313], [CA3314], or [CA3315] is displayed, perform
3 temperature sensor troubleshooting for it.
a Turn the starting switch ON and make sure that this failure code and code [A1U0N3] are not displayed.
PC360LC-10 40-137
40 Troubleshooting
Failure code [AA10NX] Air Cleaner Clogging (PC400-AA10NX-400-A-Z0-A)
Action level Failure code Air cleaner clogging

Failure
L01 AA10NX (Machine monitor system)
Detail of • Air cleaner clogging switch signal voltage was not 1 V or less while engine was running,
failure and machine monitor detected clogging of air cleaner (open of switch contacts).
Action of • Displays air cleaner clogging monitor in yellow on machine monitor.
controller
Problem on • If machine is operated as it is, engine may be damaged.
machine
• Input state (ON/OFF) from air cleaner clogging switch can be checked by using
Related monitoring function. (Code 04501 "Monitor Input 2")
information • Method of reproducing failure code: Start engine.
Clogged air cleaner
Air cleaner may be clogged. Check it for clogging and then clean or replace if
1 (when system is
clogged.
normal)
1. Turn starting switch to OFF position.
2. Disconnect connector P23 and connect T-adapter to male side.
Defective air cleaner 3. Start engine
2 clogging switch (Internal When air cleaner is
open circuit) Max. 1 z
Between P23 (male) (1) normal *1
Resistance and (2) When air cleaner is
clogged *2 Min. 1 Mz
Open circuit in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors CM02 and P23, and connect T-adapters to each
3 (wire breakage or female side.
defective contact of Between CM02 (female) (4) and P23 (female) (1) Max. 1 z
connector) Resistance
Between P23 (female) (2) and ground Max. 1 z
2. Insert T-adapters into connectors CM01 and CM02.
3. Start engine
Defective machine
4 When air cleaner is
monitor Max. 1 V
Between CM02 (4) and normal
Voltage
CM01 (3) When air cleaner is
clogged Min. 10 V
• Air cleaner suction resistance

*1: Max. -3,430 Pa {-350 mmH2O}
*2: -7,470 ± 490 Pa {-762 ± 50 mmH2O}
40-138 PC360LC-10
40 Troubleshooting
Circuit diagram related to air cleaner clogging
PC360LC-10 40-139
40 Troubleshooting
Failure code [AB00KE] Charge Voltage Low (PC400-AB00KE-400-A-Z0-A)
Action level Failure code Charging voltage low

Failure
L03 AB00KE (Machine monitor system)
Detail of • While engine is running, voltage from alternator drops, and machine monitor detects that
failure battery charge voltage is low (below 7.8 V).
Action of • Displays charge level monitor red on machine monitor.
machine • Even if cause of failure disappears, machine does not become normal until starting switch
monitor is turned to OFF position.
Problem on • If machine is operated as it is, battery may not be charged.
machine
• Signal voltage from alternator can be checked with monitoring function.
Related (Code: 04300 Charge voltage)
Loose alternator terminal or 1.Turn starting switch to OFF position.
1 open circuit at terminal 2.Check terminal.
1.Turn starting switch to OFF position.
Defective generation by 2.Insert T-adapters into connector M17.
2 alternator 3.Start engine
(when system is normal) Between M17 (2) Engine speed: Medium 27.5 to 29.5
Voltage
and ground or higher V
2. Disconnect diode D01 and connect T-adapter to male side.
3 Defective diode a Check by using multimeter in diode range.
Between D01 (male) (2) (+) and (6) (-) No continuity
Continuity
Between D01 (male) (6) (+) and (2) (-) Continuity
Defective wiring harness or 2. Insert T-adapters into connector CM01.
4 3. Start engine
machine monitor
Voltage Between CM01 (16) and ground 20 to 30 V
a If no failure is found by check on cause 2, this check is not required.
Open circuit in wiring harness 1. Turn starting switch to OFF position.
5 (wire breakage or defective 2. Disconnect connectors CM01 and M17, and connect T-adapters to
contact of connector) each female side.
Resis- Between C0M1 (female) (16) and M17
(female) (2) Max. 1 z
tance
Ground fault in wiring harness
6 2. Disconnect connectors CM01 and M17, and connect T-adapter to
(contact with ground circuit) either female side.
Resis- Between CM01 (female) (16) or M17 (female)
(2) and ground Min. 1 Mz
tance
If cause is not found by above checks, machine monitor is defective.
7 Defective machine monitor
(Since this is an internal defect, troubleshooting cannot be performed.)
40-140 PC360LC-10
40 Troubleshooting
Electrical diagram related to charging cricuit
PC360LC-10 40-141
40 Troubleshooting
Failure code [B@BAZG] Eng Oil Press Low (D65-BaBAZG-400-A-Z0-A)
Action level Failure code Engine Oil Pressure Low

Failure
L03 B@BAZG (Engine controller system)
Detail of • Engine controller determines that engine oil pressure drops abnormally because signal
failure voltage from engine oil pressure switch drops to ground level while engine is running.
Action of
machine • Lights up engine oil pressure monitor in red on machine monitor.
monitor
Problem on • If machine is used as it is, engine may be seized.
machine
• Engine oil pressure switch signal is input to engine controller that transmits information to
machine monitor through CAN communication system.
Related • For troubleshooting of engine oil pressure switch while engine is not running, see failure
information code [CA435].
• Method of reproducing failure code: Start engine.
No. Cause Procedure, measuring location, criteria, and remarks
Drop of engine oil pressure
Engine oil pressure may drops. Check it and remove cause of failure if
1 (When system works oil pressure is low.
properly)
If no failure is found by check on cause 1, engine oil pressure sensor
Defective engine oil pressure
2 system may be defective. Perform troubleshooting for failure code
sensor system
[CA435].
40-142 PC360LC-10
40 Troubleshooting
Failure code [B@BAZK] Eng Oil Level Low (PC400-BaBAZK-400-A-Z0-A)
Action level Failure code Engine oil level low

Failure
L01 B@BAZK (Machine monitor system)
Detail of • While engine is running, signal voltage from engine oil level switch is not below 1 V, so
failure machine monitor determines that engine oil level is low (oil level switch is open).
Action of • Displays engine oil level monitor yellow on machine monitor.
controller
Problem on • If machine is operated as it is, engine may seize up.
machine
• Input (ON/OFF) from engine oil level switch can be checked by using monitoring function.
Related (Code 04501: Monitor Input 2)
information • Method of reproducing failure code: Start engine
Low engine oil level
1 Check engine oil level. If it is low, remove cause.
(when system is normal)
Defective engine oil level 1. Turn starting switch to OFF position.
sensor 2. Disconnect connector P44 and connect T-adapter to male side.
2
(internal defect) Resis- Between P44 (male) (1) and ground
Max. 1 z
tance
Open circuit in wiring harness 2. Disconnect connectors CM02 and P44, and connect T-adapters to
3 (wire breakage or defective each female side.
contact of connector) Resis- Between CM02 (female) (2) and P44 (female)
(1) Max. 1 z
tance
If no failure is found by above checks, machine monitor is defective.
• Reference
2. Disconnect connectors CM01 and CM02 and connect T-adapters to
4 Defective machine monitor each female side.
Between CM02 (female) (2) and CM01 (female)
Voltage Max. 1 V
(3)
Circuit diagram related to engine oil level
PC360LC-10 40-143
40 Troubleshooting
Failure code [B@BCNS] Eng Water Overheat (PC400-BaBCNS-400-A-Z0-A)
Action level Failure code Engine Water Overheat

Failure
L02 B@BCNS (Engine controller system)
Detail of • While engine is running, voltage from engine coolant temperature sensor drops, so engine
failure controller determines that engine coolant is overheated.
Action of • Displays engine coolant temperature monitor red on machine monitor.
controller
Problem on • If machine is operated as it is, engine may seize up.
machine
• Signal voltage of engine coolant temperature sensor is input to engine controller that
transmits information to machine monitor through CAN communication system.
Related • Engine coolant temperature can be checked with monitoring function
information (Code: 04107 Engine coolant temperature)
Overheating of engine
1 coolant Engine coolant may overheat. Check it and remove cause if it overheats.
(when system is normal)
If no failure is found by checks on cause 1, engine coolant temperature
Defective engine coolant
2 sensor system may be defective. Carry out troubleshooting for failure
temperature sensor system
codes [CA144] and [CA145].
40-144 PC360LC-10
40 Troubleshooting
Failure code [B@BCZK] Eng Water Level Low (PC400-BaBCZK-400-A-Z0-A)
Action level Failure code Radiator coolant level low

Failure
L01 B@BCZK (Machine monitor system)
• While starting switch is at ON position (with engine stopped) or engine is running, radiator
Detail of coolant level switch signal voltage does not remain below 1 V, so machine monitor
failure determines that radiator coolant level is low (sensor contact is open).
Action of • Displays radiator coolant level monitor in yellow on machine monitor.
controller
Problem on • If machine is operated as it is, engine may overheat.
machine
• Input (ON/OFF) from radiator coolant level switch can be checked with monitoring
Related function. (Code: 04500 "Monitor Input 1")
Lowered radiator
coolant level Check radiator sub tank for lowering of coolant level. If coolant level is low,
1
(when system works add coolant.
properly)
Defective coolant level 2. Disconnect connector P24 and connect T-adapters to male side.
2 switch Between FULL and LOW
(internal defect) Between P24 (male) (1) Max. 1 z
Resistance and (2) lines
Below LOW line Min. 1 Mz
Open circuit in wiring 2. Disconnect connectors CM02 and P24, and connect T-adapters to each
harness female side.
3
(open circuit or a Add coolant.
defective contact) Between CM02 (female) (3) and P24 (female) (1) Max. 1 z
Resistance
Between P24 (female) (2) and ground (T09) Max. 1 z
• Reference
Defective machine 2. Insert T-adapters into connector CM02.
monitor
Between FULL and LOW
Between CM02 (3) and Max. 1 V
Voltage lines
CM01 (3)
Below LOW line Min. 10 V
PC360LC-10 40-145
40 Troubleshooting
Circuit diagram related to radiator coolant level switch
40-146 PC360LC-10
40 Troubleshooting
Failure code [B@HANS] Hyd Oil Overheat (PC400-BaHANS-400-A-Z0-A)
Action level Failure code Hydraulic oil overheat

Failure
L02 B@HANS (Pump controller system)
Detail of • While engine is running, overheating of hydraulic oil (above approx. 102 °C ) is detected
failure from signal voltage of hydraulic oil temperature sensor.
Action of • Displays hydraulic oil temperature monitor red on machine monitor.
controller • If cause of failure disappears, machine becomes normal by itself.
Problem on • If machine is operated as it is, hydraulic components may be damaged.
machine
• Signal of hydraulic oil temperature sensor is input to pump controller and then the data is
transmitted to machine monitor through CAN communication system.
Related • Hydraulic oil temperature can be checked with monitoring function
information (Code: 04401 Hydraulic oil temperature)
• See E-mode troubleshooting E-21 and E-22 in "Hydraulic oil temperature gauge display".
Overheating of hydraulic oil
1 (when system works Hydraulic oil may overheat. Check it and remove cause if it overheats
properly)
If no failure is found by check on cause 1, hydraulic oil temperature
Defective hydraulic oil
2 monitoring system may be defective. Perform troubleshooting for failure
temperature gauge system
code [DGH2KB].
PC360LC-10 40-147
40 Troubleshooting
Failure code [CA115] Eng Ne and Bkup Speed Sens Error (PC400-CA115-400-A-Z0-A)
Action level Failure code Engine Ne and Bkup Speed Sensor Error
Failure
L04 CA115 (Engine controller system)
Detail of • Abnormality is detected in signal circuits of Ne and Bkup speed sensors at the same time.
failure
Action of • Stops engine.
controller
Problem on • Engine does not start (if engine is stopped).
machine • Engine stops (if engine is running).
Related • Method of reproducing failure code: Start engine.
information
Defective Ne speed sensor
1 Perform troubleshooting for failure code [CA689].
system
Defective Bkup speed sensor
system
If no failure is found by above checks, engine controller is defective.
3 Defective engine controller
40-148 PC360LC-10
40 Troubleshooting
Failure code [CA122] Chg Air Press Sensor High Error (D65-CA122-400-A-Z0-A)
Action
Failure code Charge Air pressure sensor high error
level Failure
(Engine controller system)
L03 CA122
Detail of • High voltage is detected in pressure signal circuit of charge (boost) pressure &
failure temperature sensor.
• Takes it that charge (boost) pressure is at calculated value and allows engine to run.
Action of • Restricts engine output and allows engine to run.
controller • Closes EGR valve.
• Stops regeneration control by KDPF.
Problem on • Engine output lowers.
machine
• Input voltage from charge (boost) pressure sensor can be checked with monitoring
function.
(Code: 36501 (V))
• Charge (boost) pressure sensed by charge (boost) pressure sensor can be checked with
monitoring function.
Related (Code: 36500 (kPa))
• Since troubleshooting "socket" for this sensor features female connector only, it is not
usable for checking open circuit in wiring harness and voltage at sensor connector (not
designed for T-adapter).
• If sensor connector is disconnected, code [CA123] for "Low Error" is displayed, even in
normal condition.
Defective wiring harness 2. Turn starting switch to ON position.
1
connector If this failure code does not appear, wiring harness connector is
defective.
Defective sensor power If failure code [CA187] or [ CA227] is also displayed, perform
2 troubleshooting for it first.
source 2 circuit
2. Disconnect connector BOOST PRESS & IMT.
If failure code changes from [CA122] to [CA123] ,boost pressure sensor
is defective.
a Failure code [CA153] for temperature sensor is displayed at the
Defective boost pressure & same time.
3 temperature sensor Ignore this failure code since it appears because of disconnection of
sensor.
• Reference
2. Insert T-adapter in connector ECM J1.
Sensor 0.3 to 4.7
Voltage Between ECM J1 (15) and (59)
output V
2. Disconnect connectors ECM J1 and BOOST PRESS & IMT, and
Short circuit in wiring harness connect T-adapter to female side of ECM J1.
4
Min. 100
Resis- Between ECM J1 (female) (15) and (60)
kz
tance
PC360LC-10 40-149
40 Troubleshooting

2. Disconnect connector BOOST PRESS & IMT, and connect T-
Hot short circuit in wiring adapter to connector ECM J1.
5 3. Turn starting switch to ON position (with connector BOOST PRESS
harness
& IMT disconnected).
Voltage Between ECM J1 (15) and (59) Max. 1 V
(Since this is internal defect, troubleshooting cannot be performed.)
Circuit diagram related to boost pressure sensor
40-150 PC360LC-10
40 Troubleshooting
Failure code [CA123] Chg Air Press Sensor Low Error (D65-CA123-400-A-Z0-A)
Action
Failure code Charge air pressure sensor low error
level Failure
L03 CA123
Detail of • Low voltage is detected in pressure signal circuit of charge (boost) pressure &
failure temperature sensor.
Problem on
• Engine output lowers.
machine
• Input voltage from charge (boost) pressure sensor can be checked with monitoring
function.
(Code: 36501 (V))
• Charge (boost) pressure sensed by charge (boost) pressure sensor can be checked with
Related (Code: 36500 (kPa))
• Since troubleshooting "socket" for this sensor features female connector only, it is not
usable for checking open circuit in wiring harness and voltage at sensor connector (not
designed for T-adapter).
• If sensor connector is disconnected, this failure code is displayed.
connector
Defective power supply
system of charge pressure If failure code [CA187] or [CA227] is also displayed, perform
2 sensor (boost pressure troubleshooting for it first.
sensor)
2. Disconnect connectors CAM SENSOR, AMB. AIR PRESSURE,
Short circuit in wiring harness BOOST PRESS & IMT, and ECM J1.
3
3. Connect T-adapter to female side of ECM J1.
Min. 100 kz
tance
Ground fault of wiring 2. Disconnect connectors ECM J1 and BOOST PRESS & IMT, and
4 harness (contact with ground connect T-adapter to female side of ECM J1.
circuit) Resis- Between ECM J1 (female) (15) and ground
Min. 100 kz
tance
If no failure is found by the above checks, there may be open circuit in
5 Open circuit in wiring harness
wiring harness. (*)
a If causes 1 to 5 are not cause for failure and check result of cause 6
is abnormal, sensor is defective.
Defective boost pressure and
temperature sensor 1. Turn starting switch to OFF position.
6 (improper input voltage to 2. Insert T-adapter in connector ECM J1.
engine controller) 3. Turn starting switch to ON position.
Sensor
Voltage Between ECM J1 (15) and (59) 0.3 to 4.7 V
output
PC360LC-10 40-151
40 Troubleshooting
*: See "Troubleshooting method for open circuit in wiring harness of pressure sensor system" of "General
information on troubleshooting".
Circuit diagram related to boost pressure sensor
40-152 PC360LC-10
40 Troubleshooting
Failure code [CA131] Throttle Sensor High Error (PC400-CA131-400-A-Z0-A)
Action level Failure code Throttle sensor high error

Failure
Detail of • High voltage appears in signal circuit of fuel dial sensor.
failure
• Uses throttle value obtained before failure detection to run engine if failure is detected
Action of with starting switch at ON position.
controller • Uses full throttle value to run engine if starting switch is set to ON position after failure
detection.
Problem on • Engine speed cannot be controlled by using fuel control dial.
machine
• Signal voltage from fuel control dial can be checked with monitoring function.
Related (Code: 03000 Fuel control dial voltage)
connector
Defective throttle sensor If failure code [CA2185] is also displayed, perform troubleshooting for it
2 power supply system first.
2. Disconnect connector P20 and connect T-adapters to male side.
Between P20 (male) (1) and (3) 4.0 to 6.0
Defective fuel control dial kz
3 (throttle sensor) Resis- Between P20 (male) (2) and (3) 0.25 to 5.0
tance kz
kz
2. Disconnect connector CE03, and connect T-adapters to female side.
Open or short circuit in wiring 4.0 to 6.0
4 Between CE03 (female) (41) and (42)
harness Resis- kz
tance Between CE03 (female) (51) and (42) 0.25 to 5.0
kz
5 Short circuit in wiring harness 2. Disconnect connectors CE03 and P20, and connect T-adapters to
either female side.
Resis- Between CE03 (female) (51) and (42), or
between P20 (female) (1) and (2) Min. 1 Mz
tance
2. Disconnect connector P20 and connect T-adapters to female side.
Hot short circuit in harness 3. Turn starting switch to ON position.
6
(contact with 24 V circuit)
Voltage Between P20 (female) (2) and ground Max. 1 V
PC360LC-10 40-153
40 Troubleshooting

• Reference
2. Insert T-adapters into connector CE03.
7 Defective engine controller 3. Turn starting switch to ON position.
4. Operate fuel control dial and perform troubleshooting.
Power 4.75 to 5.25
Between CE03 (42) and (41)
supply V
Voltage
Sensor
Between CE03 (51) and (41) 0.5 to 4.5 V
output
Circuit diagram related to throttle sensor
40-154 PC360LC-10
40 Troubleshooting
Failure code [CA132] Throttle Sensor Low Error (PC400-CA132-400-A-Z0-A)
Action level Failure code Throttle sensor low error

Failure
Detail of • Low voltage appears in fuel control dial circuit.
failure
• Uses throttle value obtained before failure detection to run engine if failure is detected with
Action of starting switch at ON position.
detection.
machine
• Signal voltage from fuel control dial can be checked with monitoring function.
Related (Code:03000Fuel Dial Sensor Volt)
connector
Defective throttle sensor If failure code [CA2186] is also displayed, perform troubleshooting for it
2 power supply system first.
Defective fuel control dial Between P20 (male) (1) and (3) 4.0 to 6.0 kz
3 (throttle sensor) 0.25 to 5.0
Resis- Between P20 (male) (2) and (3)
tance kz
kz
Open or short circuit in wiring
4 Between CE03 (female) (41) and (42) 4.0 to 6.0 kz
harness Resis-
tance Between CE03 (female) (41) and (51) 0.25 to 5.0
kz
2. Disconnect connectors CE03 and P20, and connect T-adapters to
Open circuit in wiring each female side.
harness Between CE03 (female) (42) and P20 (female)
5 Max. 1 z
(wire breakage or defective (1)
contact of connector) Resis- Between CE03 (female) (51) and P20 (female)
(2) Max. 1 z
tance
Between CE03 (female) (41) and P20 (female)
(3) Max. 1 z

Short circuit in wiring 2. Disconnect connectors CE03 and P20, and connect T-adapters to
6
harness either female side.
Resis- Between CE03 (female) (51) and (41), or
tance
PC360LC-10 40-155
40 Troubleshooting

Ground fault in wiring 2. Disconnect connectors CE03 and P20, and connect T-adapters to
7 harness either female side.
(contact with ground circuit) Re- Between CE03 (female) (51) or P20 (female) (2)
sis- and ground Min. 1 Mz
tance
• Reference
8 Defective engine controller 2. Insert T-adapters into connector CE03.
4. Operate fuel control dial and perform troubleshooting.
Between CE03 (42) and (41) Power supply 4.75 to 5.25 V
Voltage
Between CE03 (51) and (41) Sensor output 0.4 to 4.5 V
40-156 PC360LC-10
40 Troubleshooting
Failure code [CA144] Coolant Temp Sens High Error (D65-CA144-400-A-Z0-A)
Action level Failure code Coolant temperature sensor high error

Failure
Detail of • High voltage is detected in engine coolant temperature sensor signal circuit.
failure
Action of • Sets coolant temperature to fixed temperature (100 °C ),and allows engine to run.
controller
Problem on • Engine does not start easily at low temperature.

machine • Overheat prevention function does not work.
• Signal voltage from engine coolant temperature sensor can be checked with monitoring
function (Code: 04105 (V)).
• Temperature sensed by engine coolant temperature sensor can be checked with
monitoring function. (Code: 04107 (°C))
• This failure code is displayed if temperature sensor connector is disconnected.
Related
• Because troubleshooting "socket" for this sensor features female connector only, it is not
information
connectable to female connector of sensor wiring harness, and thus not usable for
checking open circuit (not designed for T-adapter).
k Drain approximately 10l l of coolant beforehand, because you may get scalded by
hot water spurting out from mounting location of coolant temperature sensor when
removing radiator cap during checking and replacing coolant temperature sensor.
1
defective.
a If this failure code appears, perform following.
2. Disconnect connector COOLANT TEMP, and connect socket to male
side.
a If coolant temperature sensor has resistance of 700 z to 37 kz with
coolant temperature above 0 °C , regard coolant temperature sensor
Defective coolant as normal.
2 temperature sensor 0 °C 30 to 37 kz
Between COOLANT TEMP (male) 9.3 to 10.7
25 °C
Resis- (A) and (B) kz
tance a Coolant temperature 50 °C 3.2 to 3.8 kz
-Resistance characteristics 80 °C 1.0 to 1.3 kz
95 °C 700 to 800 z
2. Disconnect connector ECM J1 and connect T-adapter to female side
of connector.
Open or short circuit in wiring Between ECM J1 (female) (14) and (13)
3 (coolant temperature: Min. 0 °C )
harness
Resis- 700 z to 37
tance a Resistance is the same as that shown in kz
resistance characteristics table of coolant
temperature sensor of cause 2.
If no failure is found in above checks, engine controller is defective.
PC360LC-10 40-157
40 Troubleshooting
Circuit diagram related to coolant temperature sensor
40-158 PC360LC-10
40 Troubleshooting
Failure code [CA145] Coolant Temp Sens Low Error (D65-CA145-400-A-Z0-A)
Action level Failure code Coolant temperature sensor low error

Failure
Detail of • Low voltage is detected in engine coolant temperature sensor signal circuit.
failure
Action of • Sets coolant temperature to fixed temperature (100 °C ),and allows engine to run.
controller
machine • Overheat prevention function does not work.
• Signal voltage from engine coolant temperature sensor can be checked with monitoring
• Temperature sensed by engine coolant temperature sensor can be checked with
Related
• If temperature sensor connector is disconnected, this failure code is not displayed but
information
failure code [CA144] for "High Error" is displayed.
k Drain approximately 10l l of coolant beforehand, because you may get scalded by
hot water spurting out from mounting location of coolant temperature sensor when
removing radiator cap during checking and replacing coolant temperature sensor.
1
defective.
2. Disconnect connector COOLANT TEMP, and connect socket to male
side of connector.
a If coolant temperature sensor has resistance of 700 z to 37 kz with
coolant temperature above 0 °C , regard coolant temperature sensor
as normal.
Defective coolant 0 °C 30 to 37 kz
2 temperature sensor Between COOLANT TEMP (male) 9.3 to 10.7
(A) and (B) 25 °C
kz
50 °C 3.2 to 3.8 kz
Resis- a Coolant temperature
-Resistance characteristics 80 °C 1.0 to 1.3 kz
tance
95 °C 700 to 800 z
All coolant
Between (B) and ground tempera- Min. 100 kz
ture range
of connector.
Short circuit in wiring Between ECM J1 (female) (14) and (13)
3 (coolant temperature: Min. 0 °C )
harness
Resis- 700 z to 37
tance a Resistance is the same as that shown in kz
resistance characteristics table of coolant
temperature sensor of cause 2.
PC360LC-10 40-159
40 Troubleshooting

Ground fault in wiring 2. Disconnect connectors ECM J1 and COOLANT TEMP, and connect
4 harness (contact with ground T-adapters to female side of ECM J1.
Min. 100 kz
tance
Circuit diagram related to coolant temperature sensor
40-160 PC360LC-10
40 Troubleshooting
Failure code [CA153] Chg Air Temp Sensor High Error (D65-CA153-400-A-Z0-A)
Action level Failure code Charge Air Temperature sensor High Error.
Failure
Detail of • High voltage is detected in charge (boost) temperature sensor signal circuit.
failure
• Takes it that charge temperature (boost temperature) is at calculated value and allows
engine to run.
Action of • Closes EGR valve.
controller • Restricls engine output and allows engine to run.
• Stops KDPF regeneration control.
machine • Engine output lowers.
• Signal voltage from charge temperature sensor (boost temperature sensor) can be
checked with monitoring function (Code: 18501 (V)).
• Temperature sensed by charge temperature sensor (boost temperature sensor) can be
checked with monitoring function. (Code: 18500 ( °C ))
Related • Method of reproducing failure code: Turn starting switch to ON position.
information • Because troubleshooting "socket" for this sensor features female connector only, it is not
connectable to female connector of sensor wiring harness, and thus not usable for
checking open circuit (not designed for T-adapter).
• This failure code is displayed if temperature sensor connector is disconnected.
1
defective.
2. Disconnect connector BOOST PRESS & IMT, and connect socket to
male side of connector.
a If temperature sensor has resistance of 80 z to 48 kz , regard charge
temperature sensor as normal.
Defective charge -40 °C 41 to 48 kz
2 temperature sensor -20 °C 14 to 16 kz
Between BOOST PRESS & IMT
0 °C 5.4 to 6.1 kz
Resis- (male) (3) and (4)
30 °C 1.6 to 1.8 kz
tance a Charge temperature 60 °C 560 to 600 z
-Resistance characteristics
90 °C 230 to 250 z
130 °C 80 to 90 z
of connector.
3
harness
Resis- a Use Temperature-Resistance 80 z to 48
tance characteristics table for troubleshooting on kz
cause 2.
PC360LC-10 40-161
40 Troubleshooting
Circuit diagram related to boost temperature sensor
40-162 PC360LC-10
40 Troubleshooting
Failure code [CA154] Chg Air Temp Sensor Low Error (D65-CA154-400-A-Z0-A)
Action level Failure code Charge Air Temperature sensor Low Error.
Failure
Detail of • Low voltage is detected in charge (boost) temperature sensor signal circuit.
failure
• Takes it that charge temperature (boost temperature) is at calculated value and allows
engine to run.
controller • Restricts engine output and allows engine to run.
• Signal voltage from charge temperature sensor (boost temperature sensor) can be
checked with monitoring function (Code: 18501 (V)).
• Temperature sensed by charge temperature sensor (boost temperature sensor) can be
Related checked with monitoring function. (Code: 18500 ( °C ))
• If temperature sensor connector is disconnected, this failure code is not displayed but
failure code [CA153] for "High Error" is displayed.
1
defective.
2. Disconnect connector BOOST PRESS & IMT, and connect socket to
male side of connector.
a If charge temperature sensor has resistance of 80 z to 48 kz ,
regard charge temperature sensor as normal.
-40 °C 41 to 48 kz
Defective charge -20 °C 14 to 16 kz
2 temperature sensor Between BOOST PRESS & IMT
(male) (3) and (4) 0 °C 5.4 to 6.1 kz
30 °C 1.6 to 1.8 kz
Resis- a Charge temperature
tance 60 °C 560 to 600 z
-Resistance characteristics
90 °C 230 to 250 z
130 °C 80 to 90 z
Between BOOST PRESS & IMT Whole
(male) (3) and ground range Min. 100 kz

of connector.
3
harness
Resis- a Use Temperature-Resistance 80 z to 48
tance characteristics table for troubleshooting on kz
cause 2.
Ground fault in wiring 2. Disconnect connectors ECM J1 and BOOST PRESS & IMT, and
4 harness (contact with ground connect T-adapter to female side of ECM J1.
Min. 100 kz
tance
PC360LC-10 40-163
40 Troubleshooting
Circuit diagram related to boost temperature sensor
40-164 PC360LC-10
40 Troubleshooting
Failure code [CA187] Sensor 2 Supply Volt Low Error (PC200LC_10-CA187-400-A-Z0-A)
Action level Failure code Sensor 2 Supply Voltage Low Error

Failure
Detail of • Low voltage appears in sensor power supply 2 (5 V) circuit.
failure
• Ignores signals from Bkup speed sensor and controls engine by using Ne speed sensor
signals.
• Ignores signals from ambient pressure sensor and allows engine to run taking it that
ambient pressure is at fixed value (52.44 kPa {0.53 kg/cm2}).
• Ignores signals from boost pressure sensor and allows engine to run taking it that boost
Action of pressure is at calculated value.
controller • Ignores signals from crankcase pressure sensor and allows engine to run taking it that
crankcase pressure is at fixed value (0 kPa).
• Closes EGR valve.
• Limits engine output and allows engine to run.
Problem on • Engine output decreases.
machine
information
connector
2. Disconnect following connectors one by one and turn starting switch
to ON position each time.
3. Each time troubleshooting is finished, return to step 1.
If this failure code is not displayed, disconnected sensor or engine
wiring harness is defective.
a Other failure codes (many codes) are also displayed. They are
generated because of disconnection of connector. Ignore failure
Defective sensor or wiring codes other than [CA187].
2 Sensor and wiring
harness Connector
harness
Cam (Bkup speed)
CAM SENSOR
sensor
Boost pressure sensor BOOST PRESS & IMT
Connector
Ambient pressure
AMB. AIR PRESSURE
sensor
Crankcase pressure
P57
sensor
Engine harness ECM J1
If failure codes other than this code are displayed, perform
3 Defective relevant system
troubleshooting for them.
2. Disconnect connector ECM J1 and connect T-adapters to male side.
4 Defective engine controller 3. Turn starting switch to ON position with connector ECM J1
disconnected.
Voltage Between ECM J1 (male) (60) and (59) 4.75 to 5.25
V
PC360LC-10 40-165
40 Troubleshooting
Circuit diagram related to sensor power supply 2 circuit
40-166 PC360LC-10
40 Troubleshooting
Failure code [CA221] Ambient Press Sensor High Error (D65-CA221-400-A-Z0-A)
Action
Failure code Ambient Pressure Sensor High Error
level Failure
L03 CA221
Detail of • High voltage appears in signal circuit of ambient pressure sensor.
failure
• Takes it that ambient pressure is at fixed value of 52.44 kPa (0.53 kg/cm 2) and allows
engine to run.
Action of • Limits engine output and allows engine to run.
machine
• Input voltage from ambient pressure sensor can be checked with monitoring function.
(Code: 37401 (V))
Related • Ambient pressure sensed by ambient pressure sensor can be checked with monitoring
information function. (Code: 37400 (kPa))
Defective sensor power If failure code [CA187] or [ CA227] is also displayed, perform
2 supply 1 circuit troubleshooting for it first.
2. Disconnect connector AMB. AIR PRESSURE.
If failure code [CA221] changes to [CA222], sensor is defective.
Defective ambient pressure • Reference
3
sensor 1. Turn starting switch to OFF position.
2. Insert T-adapters in connector ECM J1.
Sensor 0.5 to 4.5
output V
2. Disconnect connectors AMB AIR PRESSURE and ECM J1, and
Open circuit in wiring harness connect T-adapters to either female side.
4 (wire breakage or defective
contact of connector) a Open circuit in GND line
Between ECM J1 (female) (59) and AMB. AIR PRESSURE

2. Disconnect connectors ECM J1 and AMB AIR PRESSURE, and
5 Short circuit in wiring harness connect T-adapters to either female side.
Resis- Between ECM J1 (60) and (16), or between Min. 100
tance AMB. AIR PRESSURE (female) (1) and (3) kz
PC360LC-10 40-167
40 Troubleshooting

2. Disconnect connector AMB. AIR PRESSURE.
3. Connect T-adapters to female side of connector AMB. AIR
Hot short circuit in wiring PRESSURE or insert T-adapters into connector ECM J1.
6
harness 4. Turn starting switch to ON position with connector AMB AIR
PRESSURE disconnected.
Between ECM J1 (16) and (59), or between
Voltage Max. 1 V
AMB. AIR PRESSURE (female) (3) and (2)
Circuit diagram related to ambient pressure sensor
40-168 PC360LC-10
40 Troubleshooting
Failure code [CA222] Ambient Press Sensor Low Error (D65-CA222-400-A-Z0-A)
Action level Failure code Ambient Pressure Sensor Low Error

Failure
Detail of • Low voltage appears in signal circuit of ambient pressure sensor.
failure
• Takes it that ambient pressure is at fixed value of 52.44 kPa (0.53 kg/cm2) and allows
engine to run.
machine
• Input voltage from ambient pressure sensor can be checked with monitoring function.
(Code: 37401 (V))
• Ambient pressure sensed by ambient pressure sensor can be checked with monitoring
Related function.
information (Code: 37400 (kPa))
• This failure code appears if sensor connector is disconnected.
If failure code [CA187] or [ CA227] is also displayed, perform
troubleshooting for it first.
Defective ambient pressure 2. Disconnect connector AMB. AIR PRESSURE and connect T-
2 sensor power supply circuit adapters to female side.
Power
Between AMB. AIR PRESSURE 4.75 to
Voltage supply
(female) (1) and (2) 5.25 V
input
2. Disconnect connectors AMB AIR PRESSURE and ECM J1, and
connect T-adapters to either female side.
a If power supply input is normal in check on
cause 2, this check is not required.
Max. 10 z
Open circuit in wiring harness Between ECM J1 (female) (60) and AMB.
3 (wire breakage or defective AIR PRESSURE (female) (1)
contact of connector) Resis-
a If power supply input is normal in check on
tance
cause 2, this check is not required.
Max. 10 z
Between ECM J1 (female) (59) and AMB.
AIR PRESSURE (female) (2)
Between ECM J1 (female) (16) and AMB. AIR
PRESSURE (female) (3) (sensor output) Max. 10 z
PC360LC-10 40-169
40 Troubleshooting

Ground fault in wiring harness 2. Disconnect connectors ECM J1 and AMB. AIR PRESSURE, and
4 connect T-adapters to either female side.
(contact with ground circuit)
Resis- Between ground and ECM J1 (female) (16) or Min. 100
tance AMB. AIR PRESSURE (female) (3) kz
2. Disconnect connectors ECM J1 and AMB. AIR PRESSURE, and
5 Short circuit in wiring harness connect T-adapters to either female side.
Resis- Between ECM J1 (16) and (59), or between Min. 100
tance AMB. AIR PRESSURE (female) (2) and (3) kz
2. Insert T-adapters in connector ECM J1.
Defective ambient pressure 3. Turn starting switch to ON position.
6
sensor
Sensor 0.5 to 4.5
output V
Circuit diagram related to ambient pressure sensor
40-170 PC360LC-10
40 Troubleshooting
Failure code [CA227] Sensor 2 Supply Volt High Error (D65-CA227-400-A-Z0-A)
Action level Failure code Sensor 2 Supply Voltage High Error

Failure
Detail of • High voltage appears in sensor power supply 2 circuit.
failure
• Ignores signals from Bkup speed sensor and controls engine by using Ne speed sensor
signals.
• Ignores signals from ambient pressure sensor and allows engine to run taking it that
ambient pressure is at fixed value (52.44 kPa {0.53 kg/cm2}).
• Ignores signals from boost pressure sensor and allows engine to run taking it that boost
Action of pressure is at calculated value.
controller • Ignores signals from crankcase pressure sensor and allows engine to run taking it that
crankcase pressure is at fixed value (0 kPa).
machine
information
Abnormally high sensor
1 Perform same troubleshooting as that for failure code [CA187].
power supply 2 voltage
PC360LC-10 40-171
40 Troubleshooting
Failure code [CA234] Eng Overspeed (PC400-CA234-400-A-Z0-A)
Action level Failure code Engine Overspeed

Failure
Detail of • Engine speed is above operating range.
failure
Action of • Limits fuel injection rate until engine speed lowers to operating range.
controller
Problem on • Engine speed fluctuates.
machine
Related • Engine speed can be checked by using monitoring function. (Code: 01002 (rpm))
information • Method of reproducing failure code: Run engine at full speed.
1 Use of improper fuel Fuel used may be improper. Check it.
2 Defect in related system If another failure code is displayed, perform troubleshooting for it.
Improper use Usage of machine may be improper. Instruct operator on proper use of
3
machine.
If no problem is found by checks on causes 1 and 2, engine controller is
4 Defective engine controller defective.
40-172 PC360LC-10
40 Troubleshooting
Failure code [CA238] Ne Speed Sensor Supply Volt Error (D65-CA238-400-A-Z0-A)
Action
Failure code Ne Speed Sensor Supply Voltage Error
level Failure
L01 CA238
Detail of • Low voltage appears in power supply circuit of engine Ne speed sensor.
failure
Action of • Controls engine by using signals from engine Bkup speed sensor.
controller
• Running engine stops (when Bkup (CAM) speed sensor is also defective).
Problem on • Stopped engine cannot be started (when Bkup (CAM) speed sensor is also defective).
machine • Engine starting performance becomes deteriorated
• Engine hunts.
information
2. Disconnect connector CRANK SENSOR, and turn starting switch to
ON position.
2 Defective sensor If this failure code is not displayed, crank sensor is defective.
codes other than [CA238].
2. Disconnect harness connector ECM J1 and turn starting switch to
ON position.
3 Defective wiring harness If this failure code is not displayed, engine wiring harness is defective.
4 Defective engine controller 3. Turn starting switch to ON position with engine wiring harness
disconnected.
V
Circuit diagram related to Ne speed sensor
PC360LC-10 40-173
40 Troubleshooting
Failure code [CA239] Ne Speed Sens Supply Volt High Error (D65-CA239-400-A-Z0-A)
Action level Failure code Ne Speed Sensor Supply Voltage High Error
Failure
Detail of • High voltage appears in Ne speed sensor power supply (5 V) circuit.
failure
controller
machine • Engine starting performance becomes deteriorated
• Engine hunts.
information
2. Disconnect connector CRANK SENSOR.
If this failure code is not displayed, disconnected sensor or engine wiring
2 Defective Ne speed sensor
harness is defective.
2. Disconnect connector ECM J1.
3 Defective wiring harness If this failure code disappears, wiring harness is defective.
4 Defective engine controller 3. Turn starting switch to ON position with engine wiring harness
disconnected.
V
Circuit diagram related to Ne speed sensor
40-174 PC360LC-10
40 Troubleshooting
Failure code [CA271] IMV/PCV1 Short Error (D65-CA271-400-A-Z0-A)
Action level Failure code IMV/PCV1 Short Error

Failure
Detail of • Short circuit is detected in drive circuit of supply pump actuator (IMV).
failure
Action of • None in particular.
controller
• Engine speed does not increase from low idle speed.
machine • Common rail fuel pressure rises above command value.
information
Defective supply pump 2. Disconnect connector INLET METERING VALVE.
actuator
If failure code changes from [CA271] to [CA272] , supply pump actuator
is defective.
2. Disconnect connector ECM J1 and connect T-adapters to female
Short circuit or ground fault in side.
3 wiring harness Between ECM J1 (female) (30) and (40) 1 to 5 z
Resis-
tance Between ECM J1 (female) (30) and ground Min. 100
kz
4 Short circuit in wiring harness 2. Disconnect connectors ECM J1 and INLET METERING VALVE, and
connect T-adapters to female side of ECM J1.
Resis- Between ECM J1 (female) (30) and (40) Min. 100
tance kz
2. Disconnect connectors ECM J1 and INLET METERING VALVE, and
5 connect T-adapters to female side of ECM J1.
Between ECM J1 (female) (30) and ground Min. 100
Resis- kz
tance Between ECM J1 (female) (40) and ground Min. 100
kz
PC360LC-10 40-175
40 Troubleshooting
Circuit diagram related to IMV/PCV1
40-176 PC360LC-10
40 Troubleshooting
Failure code [CA272] IMV/PCV1 Open Error (D65-CA272-400-A-Z0-A)
Action level Failure code IMV/PCV1 Open Error

Failure
Detail of • Open circuit is detected in drive circuit of supply pump actuator.
failure
Action of None in particular.
controller
Problem on • Engine runs but its speed does not stabilize.
machine • Common rail fuel pressure rises above command value.
Related • Since female connector alone is provided for "socket" used for troubleshooting of this
information sensor, it is not connectable to female connector on sensor wiring harness side and thus
not usable for check of open circuit (not designed as T-adapter).
2. Disconnect connector INLET METERING VALVE.
Defective supply pump Between INLET METERING VALVE (male) (1)
2 1 to 5 z
actuator Resis- and (2)
tance Between INLET METERING VALVE (male) (1)
and ground Min. 100 kz

Open circuit or short circuit in 2. Disconnect connector ECM J1 and connect T-adapters to female
3 wiring harness side.
1 to 5 z
tance
Ground fault in wiring 1. Turn starting switch to OFF position.
4 harness 2. Disconnect connectors ECM J1 and INLET METERING VALVE, and
(contact with ground circuit) connect T-adapters to female side of ECM J1.
Resis- Between ECM J1 (female) (30) and ground Min. 100 kz
tance Between ECM J1 (female) (40) and ground Min. 100 kz
2. Disconnect connector INLET METERING VALVE.
3. Insert T-adapters into connector ECM J1.
Hot short circuit in wiring 4. Turn starting switch to ON position (with connector INLET
5 METERING VALVE connected) and start measurement after at least
harness
one minute.
a Average voltage is displayed because of PWM control.
Voltage Between ECM J1 (30) and (40) Max. 3 V
PC360LC-10 40-177
40 Troubleshooting
Circuit diagram related to IMV/PCV1
40-178 PC360LC-10
40 Troubleshooting
Failure code [CA281] Pump Press Balance Error (D65-CA281-400-A-Z0-A)
Action
Failure code Supply pump pressure balance error
level Failure
L03 CA281
Detail of • Response of fuel force feed is poor due to high pressure pump mechanical system error.
failure
controller
Problem on • Engine does not start. Engine runs but its speed does not stabilize.
machine • The pressure of high-pressure fuel differs between front and rear side of supply pump.
information
Bleed air from the fuel circuit. For detail, see Testing and adjusting,
1 Mixing of air in fuel circuit
"Bleeding air from fuel circuit".
See descriptions of wiring harness and connectors in "c: Electrical
2 Defective harness connector equipment" in "Checks before troubleshooting" of "General information
on troubleshooting", and check it.
If no problem is found in checks on causes 1 to 2, engine controller may
3 Defective engine controller be defective.
PC360LC-10 40-179
40 Troubleshooting
Failure code [CA295] Ambient Pressure Sensor In Range Error (D65-CA295-400-A-

Z0-A)
Action level Failure code Ambient Pressure Sensor In Range Error

Failure
Detail of • Ambient pressure sensor output value displayed is out of normal range.
failure
• Fixes ambient pressure to 52.44 kPa (0.53 kg/cm2 ) and allows engine to run.
machine
• Input voltage from ambient pressure sensor can be checked by using the monitoring
function.
(Code: 37401 (V))
Related • Ambient pressure sensed by ambient pressure sensor can be checked with monitoring
information function.
(Code: 37400 (kPa))
Defective ambient pressure
1 Perform troubleshooting for failure codes [CA221] and [CA222].
sensor system
40-180 PC360LC-10
40 Troubleshooting
Failure code [CA322] Inj #1(L#1) Open/Short Error (D65-CA322-400-A-Z0-A)
Action level Failure code Injector #1(L#1) Open/Short Error

Failure
Detail of • Open or short circuit is detected in drive circuit of No. 1 injector.
failure
controller
Problem on • Engine runs with poor combustion or hunts.
machine • Engine output decreases.
Related • While engine is running normally, approx. 65 V of pulse voltage is supplied to injector (+)
information side. Because it is pulse voltage, it cannot be measured by using multimeter.
2. Disconnect connector INJECTOR CYL 1 & 2 and connect T-adapters
to male side.
2 Defective No. 1 injector Between INJECTOR CYL 1 & 2 (male) (3)
Max. 2 z
Resis- and (4)
tance Between INJECTOR CYL 1 & 2 (male) (3)

Open circuit or ground fault in
3 side.
wiring harness
Resis- Between ECM J1 (female) (48) and (58) Max. 2 z
Open circuit in wiring harness 2. Disconnect connectors ECM J1 and INJECTOR CYL 1 & 2, and
4 (wire breakage or defective connect T-adapters to each female side.
contact of connector) Between ECM J1 (female) (48) and
Max. 2 z
Resis- INJECTOR CYL 1 & 2 (female) (3)
tance Between ECM J1 (female) (58) and
INJECTOR CYL 1 & 2 (female) (4) Max. 2 z

5 harness 2. Disconnect connectors ECM J1 and INJECTOR CYL 1 & 2, and
(contact with ground circuit) connect T-adapters to either female side.
Resis- Between ground and ECM J1 (female) (48)
or INJECTOR CYL 1 & 2 (female) (3) Min. 100 kz
tance
PC360LC-10 40-181
40 Troubleshooting

2. Disconnect connectors ECM J1 and INJECTOR CYL1 & 2, and
a Check by using multimeter in continuity mode.
Short circuit in wiring harness No continuity
6 Between ECM J1 (female) (48) and each pin
other than pin (48) (No sound is
heard)
Continuity
No continuity
Between ECM J1 (female) (58) and each pin
heard)
Defective injector of other If failure codes of other injectors are displayed, perform troubleshooting
7 cylinder for them first.
Defective injector harness of If failure codes of other injectors are displayed, perform troubleshooting
8 other cylinder for them first.
Circuit diagram related to injector #1
40-182 PC360LC-10
40 Troubleshooting
Action level Failure code Injector #5(L#5) Open /Short Error

Failure
failure
controller
to male side.
Max. 2 z
Resis- and (4)

3 side.
wiring harness
4 (wire breakage or defective connect T-adapters to either female side.
Max. 2 z

tance
PC360LC-10 40-183
40 Troubleshooting

2. Disconnect connectors ECM J1 and INJECTOR CYL 5 & 6, and
heard)
Continuity
No continuity
heard)
40-184 PC360LC-10
40 Troubleshooting

Failure
failure
controller
to male side.
Max. 2 z
Resis- and (4)

3 side.
wiring harness
Max. 2 z

tance
PC360LC-10 40-185
40 Troubleshooting

heard)
Continuity
No continuity
heard)
40-186 PC360LC-10
40 Troubleshooting
Action level Failure code Injector #6(#6) Open/Short Error

Failure
failure
controller
to male side.
Max. 2 z
Resis- and (2)

3 side.
wiring harness
Max. 2 z

tance
PC360LC-10 40-187
40 Troubleshooting

heard)
Continuity
No continuity
heard)
40-188 PC360LC-10
40 Troubleshooting

Failure
failure
controller
to male side.
Max. 2 z
Resis- and (2)

3 side.
wiring harness
Open circuit in wiring harness 2. Disconnect connectors ECM J1 and INJECTOR CYL1 & 2, and
Max. 2 z

tance
PC360LC-10 40-189
40 Troubleshooting

2. Disconnect connectors ECM J1 and INJECTOR CYL1 & 2, and
heard)
Continuity
No continuity
heard)
40-190 PC360LC-10
40 Troubleshooting

Failure
failure
controller
to male side.
Max. 2 z
Resis- and (2)

3 side.
wiring harness
Max. 2 z

tance
PC360LC-10 40-191
40 Troubleshooting

heard)
Continuity
No continuity
heard)
40-192 PC360LC-10
40 Troubleshooting
Failure code [CA343] ECM Critical Internal Failure (PC400-CA343-400-A-Z0-A)
Action level Failure code ECM Critical Internal Failure

Failure
Detail of • Engine controller has internal defect.
failure
controller
Problem on • Engine continues to run normally, but it may stop during running or may not be able to
machine start if it is stopped.
• Power supply voltage of engine controller can be checked with monitoring function.
Related (Code: 03203)
information • Method of reproducing failure code: Turn starting switch to ON position
Defective engine
controller system
PC360LC-10 40-193
40 Troubleshooting
Failure code [CA351] Injectors Drive Circuit Error (PC400-CA351-400-A-Z0-A)
Action level Failure code Injectors Drive Circuit Error

Failure
Detail of • Injector drive circuit is defective.
failure
Action of • Limits engine output (limits common rail pressure) and allows engine to run.
controller
machine
information
Check failure code (injector system failure code) that is displayed at the
1 Defect in related system
same time. If another code is displayed, perform troubleshooting for it.
Defective engine controller
system
40-194 PC360LC-10
40 Troubleshooting
Failure code [CA352] Sensor 1 Supply Volt Low Error (D65-CA352-400-A-Z0-A)
Action level Failure code Sensor 1 Supply Voltage Low Error

Failure
Detail of • Low voltage appears in sensor power supply 1 (5 V) circuit.
failure
• Ignores signals from exhaust manifold pressure sensor, closes EGR valve, and limits
Action of engine output.
controller • Ignores signals from EGR valve lift sensor and KVGT position sensor, takes it that they
remain at values before failure detection, and allows engine to run..
machine
information
2. Disconnect following connectors one by one and turn starting switch
to ON position each time.
3. Each time troubleshooting is finished, return to step 1.
If this failure code is not displayed, disconnected sensor or engine
harness is defective.
Defective sensor or wiring
2 a Other failure codes (many codes) are also displayed. They are
harness
Exhaust manifold pressure sensor EXHAUST PRESSURE
EGR valve lift sensor SEGR
Connector
KVGT position sensor SVGT
Engine harness ECM J2
If failure codes other than this code are displayed, perform
3 Defective relevant system
troubleshooting for them.
4 Defective engine controller 3. Turn starting switch to ON position with connector ECM J2
disconnected.
V
PC360LC-10 40-195
40 Troubleshooting
40-196 PC360LC-10
40 Troubleshooting
Failure code [CA356] Mass Air Flow Sensor High Error (PC200LC_10-CA356-400-A-Z0-A)
Action level Failure code Mass Air Flow Sensor High Error
Failure
Detail of • High frequency is input to mass air flow sensor signal circuit.
failure
• Takes it that mass air flow is at fixed value (10 kg/min) and allows engine to run.
controller • Limits engine output and allows engine to run.
machine
• Since sensor output is 5 V pulse voltage, it cannot be measured by using multimeter.
Related • Mass air flow sensor and intake air temperature sensor are integrated.
Defective sensor power If failure code [CA3419] or [CA3421] is also displayed, perform
2 supply system troubleshooting for it first.
Defective mass air flow 2. Disconnect connector P55.
3 sensor 3. Turn starting switch to ON position.
(internal defect) If this failure code changes to [CA357], mass air flow sensor is
defective.
1. Be ready with starting switch at OFF position.
2. Disconnect connector P55, and connect T-adapters to female side.
Defective sensor power
supply system
Power Approx. 12
Voltage Between P55 (female) (2) and (3)
supply V
Open circuit in wiring harness 2. Disconnect connectors ECM J1 and P55, and connect T-adapters to
contact of connector) a To check open circuit in GND line
Resis- Between ECM J1 (female) (22) and P55
tance
2. Disconnect connectors ECM J1 and P55, and connect T-adapters to
female side of ECM J1.
6 Short circuit in wiring harness
Resis- Between ECM J1 (female) (23) and each pin Min. 100
tance other than pin (23) kz
PC360LC-10 40-197
40 Troubleshooting
Circuit diagram related to mass air flow sensor
40-198 PC360LC-10
40 Troubleshooting
Failure code [CA357] Mass Air Flow Sensor Low Error (PC200LC_10-CA357-400-A-Z0-A)
Action level Failure code Mass Air Flow Sensor Low Error
Failure
Detail of • Low frequency is input to mass air flow sensor signal circuit.
failure
• Takes it that mass air flow is at fixed value (10 kg/min) and allows engine to run.
machine
• Since sensor output is 5 V pulse voltage, it cannot be measured by using multimeter.
• Mass air flow sensor and intake air temperature sensor are integrated.
Related • If sensor connector is disconnected, both this failure code and failure code [CA691] are
information displayed.
2 supply system troubleshooting for it first.
Defective mass air flow 2. Replace mass air flow sensor.
(internal defect) If this failure code does not appear, original mass air flow sensor is
defective.
2. Disconnect connector P55, and connect T-adapters to female side.
supply system
Power Approx. 12
supply V
each female side.
a If no failure is found by check on cause 4,
this check is not required. Max. 10 z
Open circuit in wiring harness Between ECM J1 (female) (21) and P55
5 (wire breakage or defective (female) (2)
tance
Between ECM J1 (female) (22) and P55
(female) (3)

Ground fault in wiring harness either female side.
6
(contact with ground circuit) Min. 100
Resis- Between ground and ECM J1 (female) (23) or
P55 (female) (1) kz
tance
PC360LC-10 40-199
40 Troubleshooting

Resis- Between ECM J1 (female) (23) and each pin Min. 100
tance other than pin (23) kz
Hot short circuit in wiring 2. Disconnect connector P55, and connect T-adapters to female side.
8 harness 3. Turn starting switch to ON position.
(contact with 24 V circuit) a Ignore displayed failure codes.
Voltage Between P55 (female) (1) and (3) Max. 1 V
40-200 PC360LC-10
40 Troubleshooting
Failure code [CA386] Sensor 1 Supply Volt High Error (D65-CA386-400-A-Z0-A)
Action level Failure code Sensor 1 Supply Voltage High Error

Failure
Detail of • High voltage appears in sensor power supply 1 circuit.
failure
• Ignores signals from exhaust manifold pressure sensor, closes EGR valve, and limits
Action of engine output.
controller • Ignores signals from EGR valve lift sensor and KVGT position sensor, takes it that they
remain at values before failure detection, and allows engine to run..
machine
information
Abnormally high sensor
supply voltage
PC360LC-10 40-201
40 Troubleshooting
Failure code [CA428] Water in Fuel Sensor High Error (PC300-CA428-400-A-Z0-A)
Action level Failure code Water-in-fuel sensor high error

Failure
Detail of • High voltage appears in signal circuit of water-in-fuel sensor installed to fuel pre-filter.
failure
controller
Problem on • Water separator monitor is not displayed correctly.
machine
• Signal (ON/OFF) from water-in-fuel sensor of fuel pre-filter can be checked with
Related monitoring function.
information (Code: 18800)
1
defective.
Defective water-in-fuel sensor 2. Disconnect connector P47 and connect T-adapters to male side.
2 installed to fuel pre-filter a If water is in water separator, drain it.
Resistance Between P47 (male) (1) and (2) 10 to100 kz
Short circuit or ground fault in 2. Disconnect connector ECM J1 and connect T-adapter to female
3 wiring harness side of connector.
Between ECM J1 (female) (24) and (32)
Resistance (Water sensor resistance) 10 to100 kz
a If no failure is found in checks on cause 3, this check is not required.

1. Be ready with starting switch to OFF position.
Open circuit in wiring harness 2. Disconnect connectors ECM J1 and P47, and connect T-adapters to
contact of connector) Between ECM J1 (female) (32) and P47
Resistance

5 Short circuit in wiring harness a Check with multimeter in continuity mode.
No continuity
Between ECM J1 (female) (24) and every
Continuity (no sound is
pin other than (24)
heard.)
40-202 PC360LC-10
40 Troubleshooting
Circuit diagram related to water-in-fuel sensor
PC360LC-10 40-203
40 Troubleshooting
Failure code [CA429] Water in Fuel Sensor Low Error (PC300-CA429-400-A-Z0-A)
Action level Failure code Water-in-fuel sensor low error

Failure
Detail of • Low voltage appears in signal circuit of water-in-fuel sensor installed to fuel pre-filter.
failure
controller
Problem on • Water separator monitor is not displayed correctly.
machine
• Signal (ON/OFF) from water-in-fuel sensor of fuel pre-filter can be checked with
Related monitoring function.
1
defective.
Defective water-in-fuel
2 sensor installed to fuel pre- a If water is in water separator, drain it.
filter Between P47 (male) (1) and (2) 10 to100
Resis- kz
tance Between P47 (male) (1) and ground Min. 100 kz
Short circuit or ground fault in of connector.
3 wiring harness Between ECM J1 (female) (24) and (32) 10 to100
Resis- (water-in-fuel sensor resistance) kz
tance
Between ECM J1 (female) (32) and ground Min. 100 kz
1. Be ready with starting switch to OFF position.

No
Between ECM J1 (female) (24) and every pin continuity
Continuity
other than (24) (no sound
is heard.)
5 harness (contact with ground 2. Disconnect connectors ECM J1 and P47, and connect T-adapters to
circuit) either female side.
P47 (female) (1) Min. 100 kz
tance
40-204 PC360LC-10
40 Troubleshooting
Circuit diagram related to water-in-fuel sensor
PC360LC-10 40-205
40 Troubleshooting
Failure code [CA435] Eng Oil Press Sw Error (D65-CA435-400-A-Z0-A)
Action level Failure code Engine Oil Pressure Switch Error

Failure
Detail of • Failure occurs in engine oil pressure switch signal circuit.
failure
controller
Problem on • Protection function based on engine oil pressure does not work.
machine • Engine oil pressure monitor is not displayed normally.
• Method of reproducing failure code: Turn starting switch to ON position or start engine.
• Engine oil pressure switch is in CLOSED (ON) when oil pressure is low (when engine is
stopped), but is in OPEN (OFF) when oil pressure is high (when engine is running).
• To generate this failure code, engine controller checks whether engine oil pressure switch
is in CLOSED (ON) only when engine is stopped, that is, whether signal voltage is zero or
Related not.
information • Failure of engine oil pressure switch when engine is running is indicated by failure code
[B@BAZG].
k When performing checking and replacement of engine oil pressure switch, open oil
filler port, and check that engine oil temperature cools down enough not to get
scalded.
2. Disconnect connector OIL PRESSURE SWITCH and connect T-
Defective engine oil
2 adapters to male side.
pressure switch
Resis- Between OIL PRESSURE SWITCH (male) (1)
and ground Max. 10 z
tance
Open circuit or ground fault 2. Disconnect connector ECM J1 and connect T-adapters to female
3 in wiring harness side.
Resis- Between ECM J1 (female) (31) and ground
Max. 10 z
tance
Circuit diagram related to engine oil pressure switch
40-206 PC360LC-10
40 Troubleshooting
Failure code [CA441] Battery Voltage Low Error (PC300-CA441-400-A-Z0-A)
Action level Failure code Battery voltage low error

Failure
Detail of • Low voltage appears in controller power supply circuit.
failure
Action of • Sets power supply voltage to fixed value (24 V) and allows engine to run.
controller
machine start if it is stopped.
• Power supply voltage to engine controller can be checked with monitoring function.
Related (Code: 03203" Battery power supply")
information • Method of reproducing failure code: Turn starting switch to ON position
Loose or corroded battery Battery cable terminal may be loose or corroded. Check it.
1
terminal
Loose terminal or partial open 1. Turn starting switch to OFF position.
2
circuit at terminal Check terminals of alternator, battery relay, ground terminal (T12), etc.
3
defective.
1. Turn starting switch to OFF position, then perform troubleshooting.
4 Improper battery voltage 2. Measure voltage while cranking engine.
Voltage Between battery terminals (+) and (-). 20 to 30 V
2. Insert T-adapters in connector J01 (19).
5 Defective alternator 3. Start engine (Engine speed: Middle or faster).
Voltage Between J01 (19) and ground 26 to 30.5
V
• Reference
1. Turn starting switch to OFF position, and set battery disconnect
switch to OFF position.
2. Insert T-adapters into connector CE03.
6 Defective engine controller 3. Turn the battery disconnect switch to the ON position.
4. Measure voltage with starting switch at OFF position and when
starting engine.
Between CE03 (1) and (21) 20 to 30 V
Voltage
PC360LC-10 40-207
40 Troubleshooting
Circuit diagram related to engine controller power supply
40-208 PC360LC-10
40 Troubleshooting
Failure code [CA442] Battery Voltage High Error (PC400-CA442-400-A-Z0-A)
Action level Failure code Battery Voltage High Error

Failure
Detail of • High voltage (approximately 36 V or higher) appears in controller power supply circuit.
failure
Action of • Sets power supply voltage to fixed value (24 V) and allows engine to run.
controller
machine restart if it is stopped.
Related • Power supply voltage of engine controller can be checked with monitoring function.
Defective power supply
system of engine controller
PC360LC-10 40-209
40 Troubleshooting
Failure code [CA449] Rail Press Very High Error (D65-CA449-400-A-Z0-A)
Action
Failure code Rail Pressure Very High Error
level Failure
L03 CA449
Detail of • Excessively high pressure failure (2) occurs in common rail circuit.
failure
controller
machine
• Common rail pressure can be checked with monitoring function.
Since air mixed in low-pressure circuit is suspected, so inspect directly
1. Remove pressure pickup plug (outlet side) of fuel main filter.
2. Operate feed pump of fuel pre-filter.
Air in low pressure circuit 3. Check pressure pickup plug for fuel and air leakage.
2
• If this error occurs during the air bleeding operation after fuel filter
replacement, air is possibly remaining in fuel circuit, so continue to
run engine at low idle for approximately 3 minutes. When air
bleeding is completed, engine speed becomes stable and error
display disappears.
a For check of pressure in fuel low-pressure circuit, see "Testing fuel
pressure" in Testing and adjusting.
• Measure pressure on fuel filter outlet side.
At high idle
Fuel pressure in low- Min. 0.48 MPa
pressure circuit (When engine can be
{Min. 4.9 kg/cm2 }
started)
• Measure pressure on fuel filter inlet and outlet sides.
• Pressure drop in fuel low-pressure circuit is calculated by deducting
pressure at fuel filter outlet from pressure at fuel filter intlet.
Fuel low pressure Max. 0.08 MPa
Defective fuel low pressure At high idle
3 circuit pressure drop {Max. 1.4 kg/cm2 }
circuit devices
• Measure fuel low pressure on inlet side of gear pump of supply
pump.
Fuel suction circuit Min. -33.9 kPa
pressure (gear pump At high idle
side) {Min. 254 mmHg }

pressure (fuel At high idle
connector side) {Min. 203 mmHg }
4 Defective fuel cooler a Check for fuel leakage from fuel tube of fuel cooler, O-ring and seal
washer damages, and check valve clogging or damage.
40-210 PC360LC-10
40 Troubleshooting

2. Monitoring code: 36400 is displayed with monitoring function of
Defective common rail
5 machine monitor.
pressure sensor
Common rail pressure While engine is 0 ± 0.39 MPa
36400 stopped {0 ± 4 kg/cm2 }
Defective wiring harness equipment" in "Checks before troubleshooting" of "General information
6
connector on troubleshooting", and check it.
2. Disconnect connectors EGC3 and connect T-adapter to female side
Defective engine controller of connector.
7 ground wiring harness a Check terminal GND20 for looseness and rusting.
Resis- Between ground and each of EGC3 (female)
(31) and (32) Max. 10 z
tance
8 Defective supply pump Supply pump is possibly defective if no failure is found in causes 1 to 9.
Circuit diagram related to GND of engine controller
PC360LC-10 40-211
40 Troubleshooting
Failure code [CA451] Rail Press Sensor High Error (D65-CA451-400-A-Z0-A)
Action level Failure code Rail pressure sensor high error

Failure
Detail of • High voltage is detected in signal circuit of common rail pressure sensor.
failure
Action of • Restricts engine output (restricts common rail pressure) and allows engine to run.
controller
machine
• Signal voltage from common rail pressure sensor can be checked with monitoring
Related • Common rail pressure sensed by common rail pressure sensor can be checked with
information monitoring function (Code: 36400 (MPa)).
• This failure code is displayed if common rail pressure sensor connector is disconnected.
1
defective.
a If failure code [CA515] or [ CA516] is also displayed, perform
Defective common rail 2. Disconnect connector FUEL RAIL PRESS and connect T-adapter to
2 pressure sensor power female side of connector.
supply system 3. Turn starting switch to ON position.
Power
Between FUEL RAIL PRESS 4.75 to
Voltage supply
(female) (A) and (B) 5.25 V
input
2. Disconnect connectors FUEL RAIL PRESS and ECM J2, and
connect T-adapter to female side each connector.
a If power supply input in checks on cause 2
is normal, this check is not required. Max. 10 z
Open circuit in wiring harness Between ECM J2 (female) (31) and FUEL RAIL
3 (wire breakage or defective PRESS (female) (A)
a If power supply input in checks on cause 2
tance
is normal, this check is not required. Max. 10 z
Between ECM J2 (female) (21) and FUEL RAIL
PRESS (female) (B)
Between ECM J2 (female) (44) and FUEL RAIL
PRESS (female) (C) (sensor output) Max. 10 z

2. Disconnect connectors FUEL RAIL PRESS and ECM J2.
4 Short circuit in wiring harness 3. Connect T-adapter to female side of ECM J2.
Resis- Between ECM J2 (female) (44) and (31) Min. 100
tance kz
40-212 PC360LC-10
40 Troubleshooting

2. Disconnect connector FUEL RAIL PRESS and connect T-adapter to
connector ECM J2.
Hot short circuit in wiring 3. Turn starting switch to ON position (with connector FUEL RAIL
5 harness PRESS disconnected).
(contact with 24 V circuit) a Pin (44) of ECM J2 is connected to 5 V circuit via resistor inside
engine controller.
Voltage Between ECM J2 (44) and (21) Approx. 5
V
a If causes 1 to 5 are not cause for failure and check result of cause 6
is abnormal, sensor is defective.
pressure sensor (defective 1. Turn starting switch to OFF position.
6 input voltage to engine 2. Insert T-adapter in connector ECM J2.
controller) 3. Turn starting switch to ON position.
Sensor 0.2 to 4.6
output V
Circuit diagram related to common rail pressure sensor
PC360LC-10 40-213
40 Troubleshooting
Failure code [CA452] Rail Press Sensor Low Error (D65-CA452-400-A-Z0-A)
Action level Failure code Rail pressure sensor low error

Failure
Detail of • Low voltage is detected in signal circuit of common rail pressure sensor.
failure
controller
machine
• Signal voltage from the common rail pressure sensor can be checked with monitoring
• Common rail pressure sensed by common rail pressure sensor can be checked with
Related monitoring function (Code: 36400 (MPa)).
• If sensor connector is disconnected even in normal condition, failure code [CA451] for
"High Error" is generated instead of this code.
1
defective.
a If failure code [CA515] or [CA516] is also displayed, perform
Defective common rail 2. Disconnect connector FUEL RAIL PRESS and connect T-adapter to
2 pressure sensor power female side of connector.
supply system 3. Turn starting switch to ON position.
Power
Between FUEL RAIL PRESS 4.75 to 5.25
Voltage supply
(female) (A) and (B) V
input
Defective common rail 2. Disconnect connector FUEL RAIL PRESS.
3 pressure sensor 3. Turn starting switch to ON position.
If failure code changes from [CA452] to [CA451], sensor is defective.
2. Disconnect connectors ECM J2 and FUEL RAIL PRESS, and
Open circuit in wiring harness connect T-adapter to female side of each connector.
contact of connector) a Open circuit of 5 V circuit
Resis- Between ECM J2 (female) (31) and FUEL
RAIL PRESS (female) (A) Max. 10 z
tance
Ground fault in wiring harness 2. Disconnect connectors ECM J2 and FUEL RAIL PRESS, and
5 (contact with ground circuit) connect T-adapter to female side of ECM J2.
Resis- Between ECM J2 (female) (44) and ground
Min. 100 kz
tance
2. Disconnect connectors ECM J2 and FUEL RAIL PRESS, and
6 Short circuit in wiring harness connect T-adapter to female side of ECM J2.
Resis- Between ECM J2 (44) and (21)
Min. 100 kz
tance
40-214 PC360LC-10
40 Troubleshooting
PC360LC-10 40-215
40 Troubleshooting
Failure code [CA488] Chg Air Temp High Torque Derate (D65-CA488-400-A-Z0-A)
Action level Failure code Charge air Temperature High Torque Derate
Failure
Detail of • Temperature signal from boost pressure & temperature sensor exceeds upper limit of
failure control temperature.
controller
machine
• Boost temperature can be checked with monitoring function.
Aftercooler cooling performance may be degraded. Check for following
points:
Drop of cooling performance
1 • Defective fan rotation
of aftercooler
• Insufficient cooling air
• Clogged aftercooler fins
Unusual rise of turbocharger Outlet temperature of turbocharger may be unusually high. Check
2 outlet temperature related parts.
Defective boost temperature
3 Perform troubleshooting for failure codes [CA153] and [CA154].
sensor system
40-216 PC360LC-10
40 Troubleshooting
Failure code [CA515] Rail Press Sens Sup Volt High Error (D65-CA515-400-A-Z0-A)
Action level Failure code Common rail pressure sensor supply voltage high error
Failure
Detail of • High voltage is detected in common rail pressure sensor power supply (5 V).
failure
controller
machine
Related • Pressure measured by common rail pressure sensor can be checked with monitoring
information function. (Code: 36400 (MPa))
1
defective.
2. Disconnect connector FUEL RAIL PRESS.
Defective common rail 3. Turn starting switch to ON position.
2 pressure sensor If this failure code does not appear anymore, sensor is defective.
(internal defect)
a Other failure codes are displayed at the same time. This happens
because connector is disconnected. So ignore other than this failure
code.
Defective wiring harness If this failure code does not appear any more, wiring harness may have
3
failure. Perform following troubleshooting.
because connector is disconnected. So ignore other than this failure
code.
Hot short circuit in wiring 2. Disconnect connector FUEL RAIL PRESS and connect T-adapter to
4 harness female side of connector.
(contact with 24 V circuit) 3. Turn starting switch to ON position.
Between FUEL RAIL PRESS (female) (A) and 4.75 to 5.25
Voltage
(B) V
2. Disconnect connector ECM J2 and connect T-adapter.
Voltage Between ECM J2 (male) (31) and (21) 4.7 to 5.25 V
PC360LC-10 40-217
40 Troubleshooting
40-218 PC360LC-10
40 Troubleshooting
Failure code [CA516] Rail Press Sens Sup Volt Low Error (D65-CA516-400-A-Z0-A)
Action level Failure code Common rail pressure sensor supply voltage low error
Failure
Detail of • Low voltage is detected in common rail pressure sensor power supply (5 V).
failure
controller
Problem on
machine
information
1
defective.
2. Disconnect connector FUEL RAIL PRESS.
Defective common rail 3. Turn starting switch to ON position.
2 pressure sensor If this failure code does not appear anymore, sensor is defective.
(internal defect)
because connector is disconnected. So ignore other codes than this
failure code.
Defective wiring harness If this failure code does not appear any more, wiring harness may be
3
defective. Perform following troubleshooting.
because connector is disconnected. So ignore other codes than this
failure code.
4 harness 2. Disconnect connectors ECM J2 and FUEL RAIL PRESS, and
(contact with ground circuit) connect T-adapter to female side of either of them.
FUEL RAIL PRESS (female) (A) Min. 100 kz
tance
a If no failrure is found in checks on cause 3, this check is not required.
Between ECM J2 (female) (21) and (31), or
Resis- between FUEL RAIL PRESS (female) (A) and
Min. 100 kz
tance (B)
2. Disconnect connector ECM J2 and connect T-adapter.
6 Defective engine controller 4.7 to 5.25
Voltage Between ECM J2 (male) (31) and (21)
V
PC360LC-10 40-219
40 Troubleshooting
40-220 PC360LC-10
40 Troubleshooting
Failure code [CA553] Rail Press High Error (D65-CA553-400-A-Z0-A)
Action
Failure code Rail Pressure High Error
level Failure
L01 CA553
Detail of • Excessively high pressure trouble (1) has occurred in the common rail circuit.
failure
controller
Problem on • Engine noise becomes louder at no or light load.
Connection of ground terminals may be defective. Check the following
terminals.
Defective connection of • Ground terminal of machine ((-) terminal of battery)
2 ground terminal • Ground terminal of engine
• Ground terminal of engine controller
• Ground terminal of starting motor
3 Perform troubleshooting for failure code [CA451], [CA452]
pressure sensor system
PC360LC-10 40-221
40 Troubleshooting
Failure code [CA555] Crankcase Press High Error 2 (D65-CA555-400-A-Z0-A)
Action level Failure code Crankcase pressure high error 1

Failure
Detail of • High pressure error (level 1) in crankcase pressure is detected.
failure
controller
Problem on
machine
• Signal voltage from crankcase pressure sensor can be checked with monitoring function.
(Code: 48401(V))
Related • Pressure sensed by crankcase pressure sensor can be checked with monitoring function.
information (Code: 48400 (MPa))
1 Clogged KCCV filter Replace KCCV filter with a new one.
When this failure code is not cleared after KCCV filter is replaced and
Blocked KCCV gas piping emulsion is found inside KCCV, KCCV blowby gas piping may be
2
blocked with emulsified matter. Perform troubleshooting for coolant
leaks.
Defective crankcase pressure Crankcase pressure sensor system may be defective. Perform
3 troubleshooting for failure codes [CA1843] and [CA1844].
sensor
40-222 PC360LC-10
40 Troubleshooting
Failure code [CA556] Crankcase Press High Error 2 (D65-CA556-400-A-Z0-A)
Action level Failure code Crankcase Pressure High Error 2

Failure
Detail of • Crankcase pressure high error (level 2) occurs.
failure
controller
machine
(Code: 48401(V))
1 Clogged KCCV filter Replace KCCV filter.
If error condition is not cleared after KCCV filter is replaced and
2 Blocked KCCV gas piping emulsion is found inside KCCV, emulsion may block KCCV blowby gas
piping. Perform troubleshooting for leakage of coolant.
Defective crankcase pressure Crankcase sensor system may be defective. Perform troubleshooting
3 for failure codes [CA1843] and [CA1844].
sensor
If error condition is not cleared after KCCV filter is replaced and failure
code of crankcase pressure high error 2 is generated in short times,
4 Increase of blowby gas
engine may be seized or turbocharger may be defective. Perform
troubleshooting for mechanical system.
PC360LC-10 40-223
40 Troubleshooting
Failure code [CA559] Rail Pump Press Low Error (D65-CA559-400-A-Z0-A)
Action
Failure code Rail Pump Pressure Low Error
level Failure
L01 CA559
Detail of • Supply pump pressure low error 1 occurs in common rail circuit.
failure
controller
• Engine does not start or engine is hard to start.
Problem on • Exhaust gas color becomes black.
1 No fuel Check fuel level.
2 Defective fuel tank breather Check fuel tank breather for clogging.
Check fuel for leakage outside. (Check visually while running engine at
3 Fuel leakage to outside
low idle).
• Measure pressure on fuel filter inlet side.
• Cranking speed: Min. 150 rpm
Fuel pressure in low- Min.0.105 MPa
During cranking
pressure circuit {Min.1.4 kg/cm2 }
• Measure pressure on fuel filter outlet side.
Fuel pressure in low- Min. 0.48 MPa
At high idle
pressure circuit {Min. 4.9 kg/cm2 }
• Measure pressure on fuel filter inlet and outlet sides.
Defective low pressure circuit
4 • Pressure drop in fuel low-pressure circuit is calculated by deducting
device (Note 1)
the pressure at fuel filter outlet from pressure at fuel filter intlet.
Fuel low pressure Max. 0.08 MPa
At high idle
circuit pressure drop {Max. 1.4 kg/cm2 }
• Measure pressure on inlet side of gear pump of supply pump.
pressure (gear pump At high idle
side) {Min. 254 mmHg }

• Measure pressure on fuel connector side.
pressure (fuel At high idle
connector side) {Min. 203 mmHg }
40-224 PC360LC-10
40 Troubleshooting

a For check of return rate from injector, see “Checking fuel return rate
and leakage” in Testing and adjusting.
During cranking
Fuel leakage from high (When engine does not Few drops/30 sec.
5 pressure connections (inside Return rate from start)
cylinder head) injector At low idle
(When engine can be Max. 70 cc/60 sec.
started)
If fuel return is excessive, check the tightening of high pressure pipe
connections by referring to "Reference".
a For check of return rate from injector, see “Checking fuel return rate
and leakage” in Testing and adjusting.
During cranking
6 Defective injector (When engine does not Few drops/30 sec.
Return rate from start)
injector At low idle
(When engine is Max. 70 cc/60 sec.
started)
a For check of fuel return rate from supply pump, see "Checking fuel
return rate and leakage" in Testing and adjusting.
During cranking
7 Defective supply pump (When engine does not Max. 320 cc/30 sec.
Fuel return rate from start)
supply pump At low idle
(When engine is Max. 350 cc/30 sec.
started)
a For check of fuel leakage from pressure limiter, see “Checking fuel
8 Defective pressure limiter return rate and leakage” in Testing and adjusting.
Leakage from pressure Max. 30 drops/min
At low idle
limiter
Air may be in low-pressure circuit. Check it according to following
procedure.
1. Remove pressure pickup plug (outlet side) of fuel main filter.
2. Operate feed pump of fuel pre-filter.
9 Air in low pressure circuit 3. Check fuel and air from pressure pickup plug for leakage level.
• If this error occurs during air bleeding after fuel filter is replaced, air
may remain in fuel circuit. Keep running engine at low idle for about
three minutes. As air is bled from fuel circuit, engine speed will be
stabilized, and error display disappears.
Note 1: To determine defective low-pressure circuit parts, perform checks for following items.
1. Clogging of fuel tank breather
2. Sticking of check valve (3) installed to cooling plate (2) of engine controller (1)
3. Leakage or clogging of low-pressure fuel piping
4. Clogging of fuel pre-filter
5. Clogging of fuel main filter
6. Replace fuel filter when problem is not removed even if no clogging is found.
Reference
PC360LC-10 40-225
40 Troubleshooting
The high pressure pipes from the common rail are connected to the injectors via high pressure connections
provided inside the cylinder head.
Since the high pressure connections are tightened with nuts (1), retighten nuts (1).
3 Nut: 50 ± 4 Nm {5 ± 0.4 kgm}
Width across flats: 24 mm
40-226 PC360LC-10
40 Troubleshooting
PC360LC-10 40-227
40 Troubleshooting
Failure code [CA595] Turbo Speed High Error 2 (D65-CA595-400-A-Z0-A)
Action level Failure code Turbocharger Speed High Error 2

Failure
Detail of • Turbocharger rotates at abnormally high speed.
failure
controller
machine
• Turbocharger speed sensed by turbocharger speed sensor can be checked with
Related monitoring function. (Code: 48100 (rpm))
Increased turbocharger
1 Turbocharger speed may increase abnormally high. Check it.
speed
2 Defective turbocharger Turbocharger may be defective. Check it.
If no failure is found by check on cause 1, turbocharger speed sensor
Defective turbocharger speed system may be defective. Perform troubleshooting for failure code
3
sensor [CA687].
40-228 PC360LC-10
40 Troubleshooting
Failure code [CA687] Turbo Speed Low Error (D65-CA687-400-A-Z0-A)
Action level Failure code Turbocharger Speed Low Error

Failure
Detail of • Turbocharger rotates at abnormally low speed.
failure
Action of • Takes it that turbocharger speed is at calculated speed and allows engine to run.
controller
Problem on
machine
• Speed sensed by turbocharger speed sensor can be checked with monitoring function.
Related (Code: 48100 (rpm))
Defective turbocharger speed 2. Disconnect connector VGT_REV and connect T-adapters to female
3 sensor side.
(internal defect) Resis- Between VGT_REV (female) (1) and (2) 600 to 1,600
tance z
Open or short circuit in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connector ECM J2 and connect T-adapters to female
4 (short circuit, wire breakage side.
or defective contact of Resis- Between ECM J2 (female) (32) and (33) 600 to 1,600
connector) tance z
2. Disconnect connectors ECM J2 and VGT_REV, and connect T-
Ground fault in wiring harness adapters to either female side.
5 Resis- Between ground and ECM J2 (female) (32)
(contact with ground circuit) Min. 100 kz
tance or VGT_REV (female) (1)
or VGT_REV (female) (2) Min. 100 kz
tance
Short circuit in wiring harness 2. Disconnect connectors ECM J2 and VGT_REV, and connect T-
6 adapters to either female side.
Resis- Between ECM J2 (female) (32) and (33), or
between VGT_REV (female) (1) and (2) Min. 100 kz
tance
Defective installation of Turbocharger speed sensor may be installed incorrectly (loose fitting) or
7 sensor or defective speed speed sensor parts (internal parts of KVGT) may be defective (due to
sensing part thermal deformation). Check them.
PC360LC-10 40-229
40 Troubleshooting
Circuit diagram related to turbocharger speed sensor
40-230 PC360LC-10
40 Troubleshooting
Failure code [CA689] Eng Ne Speed Sensor Error (D65-CA689-400-A-Z0-A)
Action
Failure code Engine Ne speed sensor error
level Failure
E03 CA689
Detail of • Abnormal signal appear in engine Ne speed sensor circuit.
failure
controller
machine • Engine is hunting.
• Starting performance is poor.
• Since inside of speed sensor is not composed of coil but hall sensor and electronic circuit,
speed sensor cannot be determined to be normal by measuring its resistance with
Related multimeter.
information • Since speed sensor outputs 5 V pulse voltage during normal operation, it cannot be
measured with multimeter.
• Speed sensor detects a portion of speed sensing ring where no tooth is located mounted
on camshaft by the rotation of crankshaft.
1
defective.
Defective Ne speed sensor If failure code [CA238] or [CA239] is displayed at the same time,
2 power supply system perform troubleshooting for it first.
Breakage or improper
Engine Ne speed sensor may be broken or may have improper
3 installation (looseness) of
installation (looseness). Check it.
engine Ne speed sensor
2. Disconnect connector CRANK SENSOR and connect T-adapter to
female side of connector.
Defective Ne speed sensor
power supply input
Power
Between CRANK SENSOR
Voltage supply 4.75 to 5.25
(female) (1) and (2) V
input
2. Disconnect connectors ECM J1 and CRANK SENSOR.
a If no failure is found in checks on cause 4,
Open circuit in wiring harness Between ECM J1 (female) (36) and CRANK
SENSOR (female) (1)
a If no failure is found in checks on cause 4,
tance
Between ECM J1 (female) (37) and CRANK
SENSOR (female) (2)
Between ECM J1 (female) (26) and CRANK
SENSOR (female) (3) Max. 10 z
PC360LC-10 40-231
40 Troubleshooting

2. Disconnect connectors ECM J1 and CRANK SENSOR.
Short circuit in wiring harness Between ECM J1 (female) (36) and (26) or
6 Min. 100 kz
Resis- CRANK SENSOR (female) (1) and (3)
tance Between ECM J1 (female) (26) and (37) or
CRANK SENSOR (female) (2) and (3) Min. 100 kz

Ground fault in harness 2. Disconnect connectors ECM J1 and CRANK SENSOR.
7
(contact with ground circuit) Resis- Between ground and ECM J1 (female) (26)or
CRANK SENSOR (female) (3) Min. 100 kz
tance
Hot short circuit in wiring 2. Disconnect connector CRANK SENSOR.
(contact with 24 V circuit) Between CRANK SENSOR (female) (3) and
Voltage Max. 1 V
ground
1. Remove Ne speed sensor (crank sensor).
2. Check speed sensor ring (R) through sensor mounting hole.
Damage or loose mounting of a A portion (A) of speed sensing ring (R) has no tooth for purpose of
9 speed sensing wheel detecting speed.
a If speed sensing ring (R) is loosened, correct it following instructions
given in "Reference".
If no failure is found in above checks, Ne speed sensor is defective.
10 Defective Ne speed sensor (Since this is internal defect, troubleshooting cannot be performed.)
11 Defective engine controller (Since this is internal defect, troubleshooting cannot be performed.)
Circuit diagram related to engine Ne speed sensor
Reference: Check of crankshaft speed sensing ring for looseness (114 Engine)
40-232 PC360LC-10
40 Troubleshooting
Remove damper, flywheel, flywheel housing and outside main cap, and check crankshaft speed sensing ring
for looseness.
a When replacing crankshaft speed sensing ring, you must remove crankshaft.
a Keep rear seal, gasket and liquid gasket LG-6 and LG-7 on hand.
Removal
1. Remove engine assembly. For details, see "Removal and installation of engine assembly" in Disassembly
and assembly.
2. Remove the followings. For details, see "Removal and installation of engine rear seal" in Disassembly and
assembly.
1) Damper
2) Flywheel
3) Flywheel housing
4) Rear seal housing
3. Remove oil pan.
4. Remove mounting bolt (2) of main cap (1).
5. Insert bolt (2) into the bolt hole of main cap (1), and shake and remove main cap (1).
a Check that the embossed letters of "BACK" on side face (A) of main cap (1) are facing the rear of
cylinder block.
(3): Speed sensing ring
6. Check mounting bolt (4) of Ne speed (crankshaft) sensing ring (3) for looseness.
a If the bolts are loosened, replace them with new bolts.
a Tighten each bolt evenly.
8 ± 2 Nm {0.8 ± 0.2 kgm}
(5): Crankshaft
PC360LC-10 40-233
40 Troubleshooting
Installation
a See the figures in "Removal" for installation.
1. Install main cap (1) with the embossed letters "BACK" facing to the rear side of cylinder block.
2 Crankshaft journal surface:
Engine oil (EO15W-40)
a Push in by hitting it lightly with a plastic hammer or rubber hammer.
2. Install main cap (1) with mounting bolt (2).
2 Mounting bolt:
3 Main cap mounting bolt:
1]: 167 ± 8 Nm {17.0 ± 0.8 kgm}
2]: Loosen 360 deg.
3]: 30.4 ± 3.0 Nm {3.1 ± 0.3 kgm}
4]: 50 ± 4.9 Nm {5.1 ± 0.5 kgm}
5]: 120 deg. ± 5 deg.
3. Install oil pan.
Tighten mounting bolts [1] to [32] sequentially.
3 Mounting bolt:
24 ± 4 Nm {2.4 ± 0.4 kgm}
4. Reinstall engine rear seal and engine assembly. For details, see "Removal and installation of engine rear
seal" and "Removal and installation of engine assembly" in Disassembly and assembly.
40-234 PC360LC-10
40 Troubleshooting
Failure code [CA691] Intake Air Temp Sens High Error (PC200LC_10-CA691-400-A-Z0-A)
Action level Failure code Intake Air Temperature Sensor High Error
Failure
Detail of • High voltage is detected in signal circuit of intake air temperature sensor.
failure
Action of • Takes it that intake temperature is at fixed value (25 °C ) and allows engine to run.
controller
Problem on
machine
• Mass air flow sensor and intake temperature sensor are integrated.
• Signal voltage from intake air temperature sensor can be checked with monitoring
Related • Temperature sensed by intake air temperature sensor can be checked with monitoring
information function. (Code: 18400 (°C))
• If sensor connector is disconnected, this failure code is displayed together with failure
code [CA357].
1
defective.
Defective intake temperature -30 °C 25 to 28 kz
2 sensor Between P55 (male) (4) and (3) 0 °C 5.5 to 6.1 kz
(internal defect) Resis-
tance a Intake temperature - resistance 25 °C 1.9 to 2.1 kz
characteristics 40 °C 1.1 to 1.2 kz
100 °C 180 to 185 z
Open or short circuit in wiring 2. Disconnect connector ECM J1 and connect T-adapter to female side
harness of connector.
3 (short circuit, wire breakage Resis- Between ECM J1 (female) (6) and (22) 180 z to 28
and defective contact of tance kz
connector) a Use Intake temperature - Resistance characteristics table for
troubleshooting on cause 2.
Hot short circuit in wiring 2. Disconnect connector P55.
harness 3. Insert T-adapters to connector ECM J1, or connect T-adapters to
4
female side of connector P55.
(Contact with 24 V circuit)
Between ECM J1 (6) and (22) or between
Voltage Max. 5.25 V
P55 (4) (female) (4) and (3)
a Check with multimeter in continuity mode.
Resis- Between ECM J1 (female) (6) and each pin
other than (6) Min. 100 kz
tance
PC360LC-10 40-235
40 Troubleshooting
Circuit diagram related to intake temperature sensor
40-236 PC360LC-10
40 Troubleshooting
Failure code [CA692] Intake Air Temp Sens Low Error (PC200LC_10-CA692-400-A-Z0-A)
Action level Failure code Intake Air Temperature Sensor Low Error
Failure
Detail of • Low voltage error is detected in signal circuit of intake air temperature sensor.
failure
Action of • Takes it that intake temperature is at fixed value (25 °C ) and allows engine to run.
controller
Problem on
machine
• Signal voltage from intake air temperature sensor can be checked with monitoring
Related • Temperature sensed by intake air temperature sensor can be checked with monitoring
• Mass air flow sensor and intake temperature sensor are integrated.
1
defective.
2. Disconnect connector P55.
If this failure code changes to failure code [CA691], intake air
temperature sensor is defective.
•
• Reference
Defective intake temperature
2 sensor
(internal defect)
-30 °C 25 to 28 kz
Between P55 (male) (4) and (3) 0 °C 5.5 to 6.1 kz
25 °C 1.9 to 2.1 kz
Resis- a Intake temperature - resistance
tance characteristics 40 °C 1.1 to 1.2 kz
100 °C 180 to 185 z
Between P55 (male) (4) and Whole
ground (sensor body) range Min. 100 kz
harness of connector.
3 (short circuit, wire breakage Resis- Between ECM J1 (female) (6) and (22) 180 z to 28
and defective contact of tance kz
connector) a Use Intake temperature - Resistance characteristics table for
troubleshooting on cause 2.
Ground fault in wiring harness 2. Disconnect connectors ECM J1 and P55, and connect T-adapters to
4 either female side.
P55 (female) (4) Min. 100 kz
tance
5 Short circuit in wiring harness female side of ECM J1.
PC360LC-10 40-237
40 Troubleshooting

Resis- Between ECM J1 (female) (6) and each pin
tance
Circuit diagram related to intake temperature sensor
40-238 PC360LC-10
40 Troubleshooting
Failure code [CA697] ECM Internal Temp Sensor High Error (PC400-CA697-400-A-Z0-
A)
Action level Failure code ECM Internal Temperature Sensor High Error
Failure
Detail of • High voltage appears in engine controller internal temperature sensor signal circuit.
failure
controller
Problem on
machine
• Temperature sensed by engine controller internal temperature sensor can be checked by
Related using monitoring function (Code: 18900(°C)).
1 Improper usage of controller Check if the controller has been used in high temperature environments.
PC360LC-10 40-239
40 Troubleshooting
Failure code [CA698] ECM Int Temp Sensor Low Error (PC400-CA698-400-A-Z0-A)
Action level Failure code ECM Internal Temperature Sensor Low Error
Failure
Detail of • Low voltage appears in engine controller internal temperature sensor signal circuit.
failure
controller
Problem on
machine
• Temperature sensed by engine controller internal temperature sensor can be checked by

Related using monitoring function (Code: 18900(°C)).

1 Improper usage of controller Check if the controller has been used in low temperature environments.
40-240 PC360LC-10
40 Troubleshooting
Failure code [CA731] Eng Bkup Speed Sens Phase Error (D65-CA731-400-A-Z0-A)
Action
Failure code Engine Bkup speed sensor phase error
level Failure
L03 CA731
Detail of • Phase error is detected in signals from engine Ne speed sensor and engine Bkup speed
failure sensor.
Action of • Continues control by using engine Ne speed sensor signal.
controller
• Engine stops during operation (when Ne speed sensor is also defective at the same
time).
Problem on • Engine can not start or engine is hard to start.
machine • Idle speed is untable.
• Exhaust gas color becomes black.
information
Damaged engine Ne speed Check engine Ne speed sensor (crankshaft sensor) as it may be
1 (crankshaft) sensor damaged.
Damaged engine Bkup speed Check engine Bkup speed sensor (camshaft sensor) as it may be
2 (camshaft) sensor damaged.
Since defective mounting or damage of speed detection ring on
crankshaft side is suspected, perform inspection according to the
Defective mounting or
3 damage of speed detection 1. Set No. 1 piston to compression top dead center (align stamping
ring on crankshaft side mark).
2. Remove Ne speed sensor (crankshaft sensor).
3. If portion (A) (portion without tooth) of speed sensing ring is visible
through sensor mounting hole, installation is correctly done.
Camshaft gear (CAMG) is used as speed sensing ring on camshaft
side. Since its inappropriate installation or damage can be the cause of
failure, check it according to the following procedure.
Defective installation or 1. Set No. 1 piston to compression top dead center (align stamping
4 breakage of camshaft gear mark).
2. Remove Bkup speed sensor.
3. If two ribs (B) of camshaft gear (CAMG) are visible through sensor
mounting hole, it is mounted normally.
Defective timing adjustment Since defective timing adjustment of crankshaft and camshaft is
5 suspected, check it .
of crankshaft and camshaft
Defective connection of ground terminal is suspected. Check following
terminals :
Defective connection of • Ground terminal of machine ((–) terminal of battery)
6 ground terminal • Ground terminal of engine
• Ground terminal of engine controller
• Ground terminal of starting motor
PC360LC-10 40-241
40 Troubleshooting
40-242 PC360LC-10
40 Troubleshooting
Failure code [CA778] Eng Bkup Speed Sensor Error (D65-CA778-400-A-Z0-A)
Action
Failure code Engine Bkup Speed Sensor Error
level Failure
L03 CA778
Detail of • Engine Bkup speed sensor signal is abnormal.
failure
Action of • Continues to control engine by using engine Ne speed sensor signal.
controller
Problem on • Engine does not start.
• Since interior portion of speed sensor is configured with hall sensor and electronic circuit
rather than coil, measurements of speed sensor resistance by using mulitimeter cannot
Related be used to determine whether sensor is normal or not.
information • Since speed sensor output is pulse voltage of 5 V in normal state, multimeter is not usable
for measurement.
• Speed sensor detects 2 ribs on side face of camshaft gear.
Defective wiring harness equipment" in "Checks before troubleshooting" of "Related information on
1
connector troubleshooting", and check it.
Defective sensor power Failure code [CA187] or [CA227 ] is also displayed, perform troubleshooting
2 supply 2 circuit for it first.
Breakage or improper
installation (loosened) of Engine Bkup speed (CAM) sensor may be broken or installed improperly
3 engine Bkup speed (loosened). Check it.
(CAM) sensor
2. Disconnect connector CAM SENSOR , and connect T-adapter to female
Improper power supply
side.
4 input to engine Bkup
speed sensor
Power Between CAM SENSOR (female) (1) Power 4.75 to 5.25
supply and (2) supply V
2. Disconnect connectors ECM J1 and CAM SENSOR, and connect T-
Open circuit in wiring adapters to each female side.
harness Between ECM J1 (female) (60) and CAM SENSOR
5 (Wire breakage or
defective contact of Resis- Between ECM J1 (female) (59) and CAM SENSOR
connector) Max. 10 z
tance (female) (2)
Between ECM J1 (female) (9) and CAM SENSOR

2. Disconnect connectors ECM J1 and CAM SENSOR, and connect T-
adapter to female side of either connector.
Short circuit in wiring
6 Between ECM J1 (female) (9) and (60) or between
harness Min. 100 kz
Resis- CAM SENSOR (female) (1) and (3)
tance Between ECM J1 (female) (9) and (59) or between
CAM SENSOR (female) (2) and (3) Min. 100 kz

harness 2. Disconnect connectors ECM J1 and CAM SENSOR, and connect T-
7 adapter to female side of either connector.
(Contact with ground
circuit) Resis- Between ground and ECM J1 (female) (9) or CAM
Min. 100 kz
tance SENSOR (female) (3)
PC360LC-10 40-243
40 Troubleshooting

Hot short circuit in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connector CAM SENSOR , and connect T-adapter to female
8 side.
(Contact with 24 V 3. Turn starting switch to ON position.
circuit)
Voltage Between CAM SENSOR (female) (3) and ground Max. 1 V
Remove engine Bkup speed (CAM) sensor, and check camshaft gear
Loosening on camshaft through hole.
9 gear a If camshaft gear (CAMG) is loosened, correct it following instructions
given in "Reference".
If no failure is found by above checks, engine Bkup speed (CAM) sensor is
Defective engine Bkup defective.
10 speed (cam) sensor
Defective engine If no failure is found by above checks, engine controller is defective. (Since
11 this is an internal defect, troubleshooting cannot be performed.)
controller
40-244 PC360LC-10
40 Troubleshooting
Circuit diagram related to engine Bkup speed sensor
Reference: Check of camshaft gear for looseness (114 Engine)

Remove pulley, damper, front seal, front cover and housing, and check camshaft gear for looseness.
a Keep the front seal, gasket, liquid gasket LG-7 and front seal tool (795-799-8120) on hand.
Removal
1. Remove the followings. For details, see "Removal and installation of engine front seal" in Disassembly
and assembly.
1) Remove fan and fan belt.
2) Remove pulley (1).
3) Remove damper (2).
(DP): Dowel pin
PC360LC-10 40-245
40 Troubleshooting
4) Remove carrier assembly (3).

5) Remove dust seal (4) and front seal (5) from carrier assembly (3).
2. Remove front cover (6).
3. Remove housing (7).
(8): Gasket
4. Check mounting bolt (10) of gear (9) of camshaft (11) for looseness.
24 ± 4 Nm{2.4 ± 0.4 kgm}
Installation
a See the figures in "Removal" for installation.
1. Install gasket (8) to housing (7) and install front cover (6).
2 Housing:
Liquid gasket (LG-7)
2. Install front seal (5) and dust seal (4) to carrier (3). For details, see "Removal and installation of engine
front seal" in Disassembly and assembly.
1) Install front seal (5) and dust seal (4) to carrier (3).
40-246 PC360LC-10
40 Troubleshooting
2) Install carrier assembly to front cover (6).

3) Install dowel pin (DP), and install damper (2).
4) Install pulley (1).
5) Install fan belt, and install the fan.
6) Install the cooling system assembly.
PC360LC-10 40-247
40 Troubleshooting
Failure code [CA1117] Persistent Data Lost Error (PC400-CA1117-400-A-Z0-A)
Action level Failure code Persistent Data Lost Error

Failure
Detail of
• Internal defect occurred in controller.
failure
controller
• Engine continues to run normally, but it may stop during running or may not be able to
Problem on start if it is stopped.
machine • Engine controller cannot store internal data correctly.
Related • Since the engine controller internal data (KDPF related, etc.) may be lost, appropriate
information actions must be taken after the system recovers from the error.
Since the power supply circuit may be defective, carry out
1 Defective power supply circuit
troubleshooting for failure code [CA441].
Improper operation of battery Battery disconnect switch may have been operated improperly.
2
disconnect switch
Actions to be
taken after See "How to perform regeneration for service" section.
recovery from
error
40-248 PC360LC-10
40 Troubleshooting
Failure code [CA1664] KDOC Malfunction (PC200LC_10-CA1664-400-A-Z0-A)
Action level Failure code KDOC Malfunction

Failure
• During KDPF regeneration, KDOC inlet temperature sensor and KDOC outlet
Detail of temperature sensor indicate similar values (temperature difference is approximately within
failure 10°C).
• Closes EGR valve
Action of • Stops KDPF regeneration control.
controller
a You can cancel above measures by "turning starting switch to OFF position once, then
turning starting switch to ON position" after failure code is generated.
machine
injury.
Related • KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet temperature when
information engine is at idle (KDPF regeneration is not executed) are approx. 100 to 250°C, and
difference between these temperatures is approx. 10°C. (KDOC inlet temperature >
KDOC outlet temperature > KDPF outlet temperature)
• When active regeneration (manual stationary regeneration) is in progress, KDOC inlet
temperature is approx. 250 to 400°C, and KDOC outlet temperature and KDPF outlet
temperature are approx. 450 to 550°C.
• KDOC inlet temperature sensor connector label "TEMP1" expressed in black embossed
letters is seen on KDPF temperature sensor consolidating box (KDOC outlet temperature
sensor connector label "TEMP2" and KDPF outlet sensor connector label "TEMP3" are
shown similarly to "TEMP1").
• As to procedure for accessing KDPF temperature sensor, see 50 Disassembly and
assembly, "Removal and installation of KDPF assembly" and "Disassembly and assembly
of KDPF".
• Engine controller stops approximately 30 seconds after starting switch is turned to the
OFF position. So when you restart engine, wait one minute minimum before turning
starting switch to the ON position again.
• When this failure code appears, perform troubleshooting according to following work flow.
A. Identification of cause and repair
Machine O
operation for B. Machine operation for clearing failure code
clearing
failure code a This failure code does not disappear by simply turning starting switch to ON position from
OFF position after repair. You must perform machine operation for clearing failure code
after repair trouble.
Defective KDOC inlet If failure code [CA3313], [CA3314], or [CA3315] is also displayed,
Defective KDOC outlet If failure code [CA3316], [CA3317], or [CA3318] is also displayed,
PC360LC-10 40-249
40 Troubleshooting

Defective wiring harness equipment" in "Checks before troubleshooting" of "General
3
connector information on troubleshooting", and check it and fix trouble as
needed.
2. Monitor signal voltages from KDOC inlet temperature sensor and
KDOC outlet temperature sensor, and note signal voltages from
respective temperature sensors in initial condition (see Related
information).
4. Disconnect either connector TEMP1 or TEMP2.
4 Short circuit in wiring harness 5. Turn starting switch to ON position.
6. Monitor signal voltages from KDOC inlet temperature sensor and
KDOC outlet temperature sensor, and note second signal voltages
from respective temperature sensors (see Related information).
If second signal voltages sensed by KDOC inlet temperature sensor and
KDOC outlet temperature sensor do not change notably (almost same
as first signal voltages), check wiring harness for short circuit
(troubleshooting for failure codes [CA3313] and [CA3316]).
5 Defective KDOC 1. Check that KDPF is installed to exhaust system.

2. Check that KDOC is installed to KDPF.
B. Machine operation for clearing failure code
1. Turn starting switch from OFF position to ON position.
2. Start engine and run it at low idle (with no load) for approximately 1 minute.
3. Use monitoring function to display KDOC inlet and outlet temperatures.
4. Use work equipment to raise either track off ground.
5. Set swing lock switch to ON position and working mode to P-mode.
6. Run that track idle off ground for continuous 15 minutes with fuel control dial at MAX position and travel
speed at Hi setting.
a To clear this failure code, KDOC inlet temperature must be 250°C or higher.
If failure code disappears after steps 1 to 6 are implemented, repair work is complete.
a When service tool "INSITE" is available, you can clear every failure code by executing "Reset All Faults"
command.
For how to use "INSITE", see "INSITE" operation manual.
If this failure code appears again after above procedures are
6 Defective engine controller implemented, engine controller is defective.
Circuit diagram related to KDOC and KDPF temperature sensors
40-250 PC360LC-10
40 Troubleshooting
Failure code [CA1691] Regeneration Ineffective (D65-CA1691-400-A-Z0-A)
Action level Regeneration Ineffective

Failure code
Failure
L03 CA1691
• Efficiency (catalyst action) of KDOC is degraded (During regeneration, normal KDOC inlet
Detail of temperature is approximately 250 to 400°C and normal KDOC outlet temperature is
failure approximately 450 to 550°C. KDOC outlet temperature does not increase to normal range
to burn the soot in KCSF.)
Action of • Limits engine output and runs engine.
controller • Stops KDPF regeneration control.
machine
injury.
engine is at idle (KDPF regeneration is not executed) are approximately 100 to 250°C,
and difference between these temperatures is approximately 10°C. (KDOC inlet
• During manual stationary regeneration (normal mode), KDOC inlet temperature is
approximately 250 to 400°C, and KDOC outlet temperature and KDPF outlet temperature
are both approximately 450 to 550°C.
Related • When manual stationary regeneration without injecting dosing fuel (KDOC drying) is in
information progress, KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet
temperature are all approximately 250 to 400°C.
sensor connector label "TEMP2" and KDPF outlet temperature sensor connector label
"TEMP3" are shown similarly to "TEMP1").
a When KDOC in KDPF is changed, perform reset procedure for KDOC change and then
finish repair.
• How to perform regeneration for service
a When soot accumulation is at level 3 or lower, the manual stationary regeneration can be
performed only from "Regeneration for Service".
1. Start the engine.
2. Make sure that machine is in safe condition.
3. From service menu of machine monitor, select "Diagnostic Tests", open "02 Regeneration
for Service", and then perform "Manual Stationary Regeneration (manual stationary
regeneration will be completed in approximately 40 minutes).
a Failure code [CA2637] may be displayed at the same time, however, perform
troubleshooting for this failure code.
• Method of reproducing failure code:
When KDOC is changed, there is no need to check completion of repair.
When KDOC is not changed, start engine and turn manual stationary regeneration switch
ON. (See cause 6.)
PC360LC-10 40-251
40 Troubleshooting

• If there is a significant difference between KDOC outlet
Defective KDOC outlet temperature and KDOC inlet temperature and KDPF outlet
1 temperature sensor temperature when KDPF is completely cool or engine running
at idle (not regenerating), replace KDOC outlet temperature
sensor.
1. Rapidly accelerate engine from low idle to high idle 2 times,
and then keep engine running at high idle for 5 seconds.
• If excessive black smoke is exhausted when accelerating
engine or running it at high idle, perform troubleshooting for "S-
2 Unusual exhaust gas color 9 KDPF gets clogged in a short time".
a It does not matter that black smoke particles are exhausted
during engine acceleration but are not exhausted during
running at high idle.
a Dry KDOC.
2. Monitor signal voltages from KDOC inlet temperature sensor
and KDPF outlet temperature sensor, note temperature values
Defective KDOC from each sensor with KDPF under initial condition and during
3 manual stationary regeneration, and check that KDOC outlet
(KDOC drying)
temperature sensor is normal. (See "Related information".)
3. Perform manual stationary regeneration. (See "Related
information".)
a Since this is for drying KDOC, dosing fuel is not injected during
regeneration.
k Perform after the KDPF and KDOC are sufficiently cooled.
1. Remove KDPF.
Defective KDOC 2. Remove KDOC.
4 3. Blow air from KDOC outlet side to clean ceramic surfaces
(dirty or cracked or damaged
inside KDOC.
KDOC surface)
4. Check ceramic inside KDOC for cracks.
If cracks are found in KDOC, KDOC is defective (replace KDOC).
a Perform the following regardless whether KDOC is replaced or
not.
1. Install KDOC and KDPF.
3. From service menu of machine monitor, display the
"Diagnostic Tests" screen, open "03 KDPF Memory Reset",
and then perform "03 Reset after KDOC change".
a When reset after KDOC change is performed, failure codes
[CA1691] and [CA2637] will not be displayed. At that time,
5 Reset after KDOC change
remedy of not injecting dosing fuel when the failure code is
displayed is released.
a Check that reset after KDOC change is completed
successfully (by reset count). If not, perform troubleshooting
again.
a When KDOC is replaced, finish troubleshooting without
performing manual stationary regeneration.
40-252 PC360LC-10
40 Troubleshooting

a Perform this troubleshooting when KDOC is not changed.
2. Monitor signal voltages from KDOC inlet temperature sensor
and KDPF outlet temperature sensor, note temperature values
from each sensor with KDPF under initial condition and during
manual stationary regeneration, and check that KDOC outlet
temperature sensor is normal. (See "Related information".)
3. Perform manual stationary regeneration. (See "Related
information".)
Defective KDOC 4. Turn starting switch to OFF position.
6 5. Start engine and perform manual stationary regeneration
(degraded KDOC catalyst action) again (to confirm that failure code [CA2637] will not be
displayed)
a Check that failure code is not displayed and finish
troubleshooting.
a If failure code [CA2637] is displayed after manual stationary
regeneration is completed, KDOC is defective (catalyst action
of KDOC is degraded. Change KDOC).
a When KDOC is changed, perform troubleshooting for cause 5
again.
PC360LC-10 40-253
40 Troubleshooting
Failure code [CA1695] Sens 5 Supply Volt High Error (PC300-CA1695-400-A-Z0-A)
Action level Failure code Sensor 5 Supply Voltege High Error

Failure
Detail of • High voltage error is detected in 5 V power supply for KDPF differential pressure sensor
failure and KDPF outlet pressure sensor.
• Takes it that KDPF outlet pressure is at fixed value (0 kPa {0 kg/cm 2 }) and allows engine
to run.
• Takes it that KDPF delta pressure is at recommended value and allows engine to run
Action of (uses delta pressure of 0 kPa in some cases) .
controller • Closes EGR valve and opens KVGT fully.
• Restricts engine output and allows engine to run.
machine
Related • KDPF delta pressure sensor and KDPF outlet pressure sensor are integrated.
1
defective.
Defective KDPF delta 2. Disconnect connector E25.
pressure (outlet pressure) 3. Turn starting switch to ON position.
2 sensor (internal a Ignore displayed failure codes other than this code.
(internal defect) If this failure code is not displayed, KDPF delta pressure (outlet
pressure) sensor is defective.
2. Disconnect connectors CE03 and E25, and connect T-adapters to
3 female side of connector CE03.
harness
Resis- Between CE03 (female) (52) and each pin
tance
2. Disconnect connector E25.
3. Insert T-adapters to connector CE03, or connect T-adapters to
4 Defective engine controller female side of connector E25
Between CE03 (female) (52) and (43), or
Voltage 4.75 to 5.25 V
between E25 (female) (4) and (1)
40-254 PC360LC-10
40 Troubleshooting
Failure code [CA1696] Sens 5 Supply Volt Low Error (PC300-CA1696-400-A-Z0-A)
Action level Failure code Sensor 5 Supply Voltege Low Error

Failure
Detail of • Low voltage appears in 5 V power supply circuit for KDPF delta pressure sensor and
failure KDPF outlet pressure sensor.
• Takes it that KDPF outlet pressure is at fixed value (0 kPa {0 kg/cm 2 }) and allows engine
to run.
• Takes it that KDPF delta pressure is at recommended value and allows engine to run
Action of (uses delta pressure of 0 kPa in some cases) .
controller • Closes EGR valve and opens KVGT fully.
• Restricts engine output and allows engine to run.
machine
Related • KDPF delta pressure sensor and KDPF outlet pressure sensor are integrated.
1
defective.
Defective KDPF delta 2. Disconnect connector E25.
pressure (outlet pressure) 3. Turn starting switch to ON position.
2 sensor (internal a Ignore displayed failure codes other than this code.
(internal defect) If this failure code is not displayed, KDPF delta pressure (outlet
pressure) sensor is defective.
Ground fault in wiring 2. Disconnect connectors CE03 and E25, and connect T-adapters to
(contact with ground circuit) Resis- Between ground and CE03 (female) (52)
orE25 (female) (4) Min. 100 kz
tance
2. Disconnect connectors CE03 andE25, and connect T-adapters to
4 female side of connector CE03.
harness
Resis- Between CE03 (female) (52) and each pin
tance
3. Insert T-adapters to connector CE03, or connect T-adapters to
5 Defective engine controller female side of connector E25
Between CE03 (female) (52) and (43), or
between E25 (female) (4) and (1)
PC360LC-10 40-255
40 Troubleshooting
40-256 PC360LC-10
40 Troubleshooting
Failure code [CA1843] Crankcase Press Sens High Error (PC200LC_10-CA1843-400-A-Z0-

A)
Action level Failure code Crankcase Pressure Sensor High Error

Failure
Detail of • High voltage appears in signal circuit of crankcase pressure sensor.
failure
Action of • Takes it that crankcase pressure is at fixed value (approximately 0 kPa) and allows engine
controller to run.
Problem on
machine
(Code: 48401(V))
2 supply circuit troubleshooting for it first.
Defective crankcase 2. Disconnect connector P57.
(internal defect) If failure code [CA1843] changes to [CA1844], crankcase pressure
sensor is defective.
Open circuit in wiring harness each female side.
Resis- Between ECM J1 (female) (59) and P57 (male)
(2) Max. 10 z
tance
5 Short circuit in wiring harness either female side.
between P57 (female) (1) and (3) Min. 100 kz
tance
harness 2. Disconnect connector P57 and connect T-adapters to female side.
Voltage Between P57 (female) (3) and (2) Max. 1 V
• Reference
7 Defective engine controller 1. Turn starting switch to OFF position.
Sensor
output
PC360LC-10 40-257
40 Troubleshooting
Circuit diagram related to crankcase pressure sensor
40-258 PC360LC-10
40 Troubleshooting
Failure code [CA1844] Crankcase Press Sens Low Error (PC200LC_10-CA1844-400-A-00-

A)
Action level Failure code Crankcase pressure sensor low error

Failure
Detail of • Low voltage error is detected in signal circuit of crankcase pressure sensor.
failure
Action of • Set crankcase pressure to the fixed value (approx. 0 kPa), and run engine.
controller
Problem on
machine
(Code: 48401(V))
Related • Crankcase pressure sensed by crankcase pressure sensor can be checked with
information monitoring function. (Code: 48400 (MPa))
connector
If failure code [CA187] or [CA227] is also displayed, perform
Defective sensor power 1. Turn starting switch to OFF position.

2 supply system 2. Disconnect connector P57 and connect T-adapters to female side.
Power 4.75 to 5.25
supply V
2. Disconnect connectors ECM J1 and P57 and connect T-adapters to
each female side.
a If any failure is found in harness, disconnect connector OEM
CONNECTION and check further to determine which is defective;
engine harness or chassis harness.
Open circuit in wiring harness a If no failure is found by check on cause 2,

Resis- this check is not required.
3 (wire breakage or defective Max. 10 z
tance Between ECM J1 (female) (60) and P57
(female) (1)
Resis- this check is not required.
Max. 10 z
tance Between ECM J1 (female) (59) and P57
(female) (2)
Resis- Between ECM J1 (female) (3) and P57
tance
PC360LC-10 40-259
40 Troubleshooting

either female side.
Ground fault in wiring
4 harness a If any failure is found in harness, disconnect connector OEM
(contact with ground circuit) CONNECTION and check further to determine which is defective;
engine harness or chassis harness.
Resis- Between ECM J1 (female) (3) or P57 (female)
(3) and ground Min. 100 kz
tance
between P57 (female) (2) and (3) Min. 100 kz
tance
Defective crankcase 2. Insert T-adapters into connector P57.
6 pressure sensor (internal 3. Turn starting switch to ON position.
defect) Sensor
Voltage Between P57 (female) (3) and (2) 0.3 to 4.7 V
output
• Reference
7 Defective engine controller 1. Turn starting switch to OFF position.
2. Insert T-adapters into connector J1.
Sensor
output
Circuit diagram related to crankcase pressure sensor
a Connector PPCV is dummy (no sensor is connected to it).
40-260 PC360LC-10
40 Troubleshooting
Failure code [CA1879] KDPF Delta P Sensor High Error (PC200LC_10-CA1879-400-A-Z0-A)
Action level Failure code KDPF delta pressure sensor high error
Failure
Detail of • High voltage appears in KDPF delta pressure sensor signal circuit.
failure
• Takes it that KDPF delta pressure is at recommended value and allows engine to run.
(If another failure code is also generated, controller may run engine using delta pressure
Action of of 0 kPa.)
machine
k Since the temperature of the KDPF will become higher than 500 °C , take care not to
get burn injury.
• KDPF delta pressure sensor and KDPF outlet pressure sensor are integrated.
Related • If failure code [CA1695] is not displayed but failure code [CA3133] is displayed, GND line
information may have open circuit (defective connection of connector).
• Signal voltage from KDPF delta pressure sensor can be checked with monitoring function.
(Code: 47101(V))
• Delta pressure sensed by KDPF delta pressure sensor can be checked with monitoring
function. (Code: 47100 (kPa))
connector
If failure code [CA1695] or [CA1696] is displayed, perform
2 supply system 2. Disconnect connector E25 and connect T-adapters to female side.
Voltage Between E25 (female) (4) and (1) 4.75 to 5.25 V
Defective KDPF delta If failure code changes to [CA1881], KDPF delta pressure sensor is
3 pressure sensor defective.
a If this failure code is still displayed, the wiring harness or engine
controller is defective.
a Ignore other displayed failure codes.
harness 2. Disconnect connectors CE03 and E25, and connect T-adapters to
4 each female side.
(wire breakage or defective
contact of connector) a To check for open circuit in GND line
Resis- Between CE03 (female) (43) and E25
tance
PC360LC-10 40-261
40 Troubleshooting

female side of connector CE03.
5 a Check by using multimeter in continuity mode.
harness
No continuity
Between CE03 (female) (55) and each other
Continuity (No sound is
pin
heard)
Circuit diagram related to KDPF delta pressure sensor
40-262 PC360LC-10
40 Troubleshooting
Failure code [CA1881] KDPF Delta P Sensor Low Error (PC200LC_10-CA1881-400-A-Z0-A)
Action level Failure code KDPF deltal pressure sensor low error
Failure
Detail of • Low voltage appears in the KDPF delta pressure sensor signal circuit.
failure
• Takes it that KDPF delta pressure is at recommended value and allows engine to run.
(If another failure code is also generated, controller may run engine using delta pressure
Action of of 0 kPa.)
machine
k Since the temperature of the KDPF will become higher than 500 °C , take care not to
get burn injury.
• If failure code [CA1696] is not displayed but failure code [CA3134] is displayed, the
Related sensor connector may be disconnected or an open circuit (poor connection in connector)
information is suspected in the 5 V line.
• This failure code is displayed if the sensor connector is disconnected.
(Code: 47101(V))
• Differential pressure sensed by KDPF delta pressure sensor can be checked with
monitoring function. (Code: 47100 (kPa))
connector
If failure code [CA1695] or [CA1696] is displayed, perform
2 supply system 2. Disconnect connector E25 and connect T-adapters to female side.
Voltage Between E25 (female) (4) and (1) 4.75 to 5.25
V
each female side.
Open circuit in wiring harness Between CE03 (female) (43) and E25
tance
Between CE03 (female) (52) and E25
(female) (4)
PC360LC-10 40-263
40 Troubleshooting

Ground fault in wiring harness 2. Disconnect connectors CE03 and E25, and connect T-adapters to
Resis- Between CE03 (female) (55) or E25 (female)
Min. 100 kz
tance (2) and ground
female side of connector CE03.
5 Short circuit in wiring harness a Check by using multimeter in continuity mode.
No continuity
Continu- Between CE03 (female) (55) and each other
ity pin (No sound is
heard)
Defective KDPF delta 2. Insert T-adapter into connector E25.
6 pressure 3. Turn starting switch to ON position.
Voltage Between E25 (2) and (1) 0.5 to 4.5 V
40-264 PC360LC-10
40 Troubleshooting
Failure code [CA1883] KDPF Delta P Sens In Range Error (PC200LC_10-CA1883-400-A-

Z0-A)
Action level Failure code KDPF Delta Pressure Sensor In Range Error
Failure
Detail of • Signal voltage from KDPF delta pressure sensor is out of range. (Signal voltage from
failure sensor is within "operating" range.)
• Takes it that KDPF delta pressure is at estimated value and allows engine to run.
(If another failure code is also generated, controller may use delta pressure of 0 kPa to
run engine.)
machine
k Since KDPF is heated to 500°C or above, take care not to get burn injury.
(Code: 47101 (V))
Related function. (Code: 47400 (°C))
information • Temperature sensed by KDPF outlet temperature sensor can be checked with monitoring
• Temperature sensed by torque converter oil temperature sensor can be checked with
a Use "Short-circuit connector: 799T-601-4611".
• As to procedure for accessing KDPF delta pressure sensor, wiring harness, and tube, see
50 Disassembly and assembly, "Removal and installation of KDPF assembly" and
"Disassembly and assembly of KDPF".
• Engine controller stops approximately 30 seconds after starting switch is turned to OFF
position. So when you restart engine, wait 1 minute minimum before turning starting
switch to ON position again.
Machine O
clearing
troubleshooting for [CA1695] or [CA1696] first.
1 supply system 2. Disconnect connector E25 and connect T-adapter to female side.
PC360LC-10 40-265
40 Troubleshooting

2
needed.
If failure code [CA1881] is not displayed, wiring harness or engine
a Perform check on cause 2 again.
Defective wiring harness or 1. Turn starting switch to OFF position.

3 engine controller 2. Disconnect connector E25 and connect short-circuit connector to
female side.
a To connect 5 V line to signal line (to short pin (4) to pin (2) of
connector E25).
Defective KDPF delta a If failure codes [CA1881] and [CA1879] are displayed in check on
4 pressure sensor cause 3, KDPF delta pressure sensor is defective.
each female side.
tance
(female) (4)

Ground fault in wiring 2. Disconnect connectors CE03 and E25, and connect T-adapter to
(contact with ground circuit) Resis- Between ground and CE03 (female) (55) or
E25 (female) (2) Min. 100 kz
tance
2. Disconnect connectors CE03 and E25, and connect T-adapter to
female side of CE03.
Between CE03 (female) (55) and No continuity (no sound
Continuity
each pin other than pin (55) is heard)
40-266 PC360LC-10
40 Troubleshooting

1. Remove KDPF delta pressure sensor tube.
2. Clean KDPF delta pressure sensor tube to clear clogging.
3. Check KDPF delta pressure sensor tube for cracks and damage.
4. Install KDPF delta pressure sensor tube with both tube ends
connected securely.
Defective KDPF delta
8 pressure sensor tube • Reference
How to check KDPF delta pressure sensor tube for clogging
2. Monitor delta pressure sensed by KDPF delta pressure sensor on
monitoring screen of machine monitor.
Code 47,100 (kPa) 0 ± 3 (kPa)
k Place the machine on a level ground.
1. Turn starting switch to ON position and leave it in that position for 1 minute. (In order to allow engine
controller to determine drift of voltage when starting switch is turned to ON position)
4. After finishing warm-up operation, set swing lock switch to OFF position, working mode to P-mode, and
fuel control dial to MAX position.
5. Perform arm IN relief for 40 seconds.
a Take care not to overheat hydraulic oil.
a If failure code disappears, repair is complete.
6. If failure code still remains displayed, repeat above step 5 three times.
a If failure code disappears, repair is complete.
command.
PC360LC-10 40-267
40 Troubleshooting
Failure code [CA1921] KDPF Soot Load High Error 1 (PC200LC_10-CA1921-400-A-Z0-A)
Action level Failure code KDPF Soot Load High Error 1

Failure
• Soot accumulation of KDPF reaches level 6 or 7. As much soot is accumulated in KCSF,
Detail of the user is requested to perform "Manual Stationary Regeneration" immediately.
failure (If soot accumulation reaches level 8, KDPF must be replaced.)
controller • Disables automatic regeneration but allows manual stationary regeneration.
machine
k Since KDOC and KDPF are heated to 500°C or above, take care not to get burn
injury.
(Code: 47101 (V))
engine is at idle (KDPF regeneration is not executed) are approx. 100 to 250°C, and
Related difference between these temperatures is approx. 10°C. (KDOC inlet temperature >
information KDOC outlet temperature > KDPF outlet temperature)
• When the active regeneration (the manual stationary regeneration) is in progress, KDOC
inlet temperature is approx. 250 to 400°C, and KDOC outlet temperature and KDPF outlet
• Soot accumulation in KDPF is classified into 8 levels. Current soot accumulation level can
be checked on machine monitor by selecting the "02 Regeneration for Service" screen.
• The manual stationary regeneration can be performed for removing soot when soot
accumulation is up to level 7.
• If soot accumulation reaches level 8, failure code [CA1922] is displayed. At this level, the
KDPF is completely clogged with soot, and inspection, cleaning, or replacement is
required.
a Time required for the manual stationary regeneration depends on the accumulated soot in
KCSF, however, it is estimated as follows.
• If soot accumulation is level 4: Approx. 40 minutes to 1 hour
• If soot accumulation is level 5: Approx. 1 to 2 hours
• If soot accumulation is level 6 or 7: Approx. 1 to 3 hours
• If soot accumulation is level 8: The manual stationary regeneration can not be performed.
40-268 PC360LC-10
40 Troubleshooting
Factors for excessive soot accumulation

1. Engine runs with light loads and cannot keep exhaust gas temperature high enough to
burn soot in KDPF.
• If temperature of the gas entered into after-treatment system (KDPF) is low, a large
amount of soot may accumulate.
• To avoid the soot accumulation in KDPF, the engine must run under high load.
2. Engine has failure that leads to excessive black smoke.
3. "Regeneration Disable" is set from the screen monitor.
• Even if the soot is accumulated, regeneration does not start automatically.
You must move the machine to a safe place to release the "Regeneration Disable",
Related and perform the regeneration.
information a Releasing method of "Regeneration Disable"
Select the "Cancel of Regeneration Disable" from the ”KDPF Regeneration” screen and
execute.
(For details, see Operation and Maintenance Manual, "Operation", "Handling KDPF",
"Operation procedure of KDPF Regeneration Disable".)
a If another failure code is displayed (including when manual stationary regeneration is in
progress), perform troubleshooting for it first.
a If failure code [CA1922] has been displayed originally, it changes to [CA1921] during
troubleshooting process of [CA1922]. In such case, refer to failure code [CA1922].
• Method of reproducing failure code: Turn starting switch to the ON position.
1. Check if the regeneration stop button is pressed down from the
machine monitor.
a If the regeneration stop button is pressed down, release it.
4. Perform manual stationary regeneration from user mode.
a When the manual stationary regeneration is finished correctly, the
Excessive KDPF (KCSF) repair is completed.
1
soot accumulation level
a If the regeneration does not complete within 3 hours, perform the
troubleshooting of [CA2639].
a Check that failure code is not displayed after manual stationary
regeneration is completed.
a If failure code [CA1922] or [CA2639] is displayed after manual
stationary regeneration is completed, proceed to checks on
cause 2.
a If failure code [CA1921], or [CA2639] is displayed after manual
stationary regeneration is completed, perform following.
a For check of the exhaust gas color, see "30 Testing and adjusting",
"Testing exhaust gas color".
a When checking the exhaust gas color, perform the "Regeneration
Disable" from the machine monitor.
1. Rapidly accelerate engine from low idle to high idle two times, and
2 Unusual exhaust gas color then keep engine running at high idle for 5 seconds.
• If excessive black smoke is exhausted when accelerating engine or
running it at high idle, perform troubleshooting for "S-9 KDPF gets
clogged in a short time".
a It does not matter that black smoke particles are exhausted during
engine acceleration but are not exhausted during running at high
idle.
a Check that no failure code appears.
PC360LC-10 40-269
40 Troubleshooting

a When you finish the check of the exhaust gas color, release
"Regeneration Disable".
40-270 PC360LC-10
40 Troubleshooting
Failure code [CA1922] KDPF Soot Load High Error 2 (PC200LC_10-CA1922-400-A-Z0-A)
Action level Failure code KDPF Soot Load High Error 2

Failure
• Soot accumulation in KDPF is very high, and machine must be stopped and performed
Detail of maintenance immediately.
failure • Soot accumulation reaches level 8 (KDPF is completely clogged with soot).
controller • Disables the automatic regeneration and the manual stationary regeneration.
machine
injury.
(Code: 47101 (V))
Related function. (Code: 47100 (kPa))
information • KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet temperature when
inlet temperature is approx. 250 to 400°C, and KDOC outlet temperature and KDPF outlet
• Soot accumulation in KDPF is classified into 8 levels. Current soot accumulation level can
be checked on machine monitor by selecting the "02 Regeneration for Service" screen.
• The manual stationary regeneration can be performed for removing soot when soot
accumulation is up to level 7.
• If soot accumulation reaches level 8, failure code [CA1922] is displayed. At this level, the
KDPF is completely clogged with soot, and inspection, cleaning, or replacement is
required.
PC360LC-10 40-271
40 Troubleshooting
• If soot accumulation is level 4: Approx. 40 minutes to 1 hour
• If soot accumulation is level 5: Approx. 1 to 2 hours
• If soot accumulation is level 6 or 7: Approx. 1 to 3 hours
• If soot accumulation is level 8: The manual stationary regeneration can not be performed.
Factors for excessive soot accumulation
1. Engine runs with light loads and cannot keep exhaust gas temperature high enough to
burn soot in KDPF.
• If temperature of the gas entered into after-treatment system (KDPF) is low, a large
amount of soot may accumulate.
• To avoid the soot accumulation in KDPF, the engine must run under high load.
2. Engine has failure that lead to excessive black smoke.
3. "Regeneration Disable" is set from the screen monitor.
• Even if the soot is accumulated, regeneration does not start automatically.
You must move the machine to a safe place to release the "Regeneration Disable",
and perform the regeneration.
a Releasing method of "Regeneration Disable"
Select the "Cancel of Regeneration Disable" from the ”KDPF Regeneration” screen and
execute.
Related
information (For details, see Operation and Maintenance Manual, "Operation", "Handling KDPF",
"Operation procedure of KDPF Regeneration Disable".)
• Procedure of performing the manual stationary regeneration from the "Regeneration for
Service".
performed only from the "Regeneration for Service".
3. From service menu of machine monitor, display the "Diagnostic Tests" screen, open
"Regeneration for Service", and then perform the "Manual Stationary Regeneration".
a Resetting after KDPF cleaning
From service menu of machine monitor, display the "Diagnostic Tests" screen, open
"KDPF Memory Reset", and then perform "KDPF Cleaning" (reset after KDPF cleaning).
a Resetting after KDPF change
From service menu of machine monitor, display the "Diagnostic Tests" screen, open
"KDPF Memory Reset", and then perform "KDPF Change" (resetting after KDPF change).
a When KCSF in KDPF is changed, always perform resetting procedures for KDPF cleaning
and KDPF change, and then perform the "Manual Stationary Regeneration" from the
"Regeneration for Service" to eliminate moisture from KCSF.
40-272 PC360LC-10
40 Troubleshooting

Increase of soot machine monitor.
1 accumulation due to a If the regeneration stop button is pressed down, release it.
"Regeneration Disable"
a After releasing the "Regeneration Disable", proceed to checks on
causes 2 and after.
• Check the abnormality record.
1. Turn starting switch to the ON position.
2. From the machine monitor, displays the abnormality record screen
and check the history of failure codes CA2639, CA1921 and
CA1922.
Interval between failure code CA2639 and CA1921
X360 sec (KOMTRAX history) or X0.1 h (Monitor history screen)
and
Interval between failure code CA1921 and CA1922
X360 sec (KOMTRAX history) or X0.1 h (Monitor history screen)
[When above conditions are satisfied]
a As much soot is accumulated, KDPF regeneration can not be
performed.
1. Replace the KCSF or the KDPF.
2. Turn the starting switch to the ON position, and perform the reset
after KDPF cleaning (see "Related information").
a Check that failure code [CA1922] is changed to [CA1921].
a If the failure code [CA1922] continues, check the resetting
Defective KDPF (KCSF)
2 procedure after KDPF cleaning, and perform the reset after KDPF
(change KCSF) cleaning again.
3. Reset the KDPF after its change (see "Related information").
4. Perform checks on causes 4 to 7 (When KDPF is changed, this is not
needed.)
7. Perform regeneration for service.
repair is completed.
a If failure code [CA1922], [CA1921] or [CA2639] is displayed after
manual stationary regeneration is completed, perform checks on
cause 8.
[When above conditions are not satisfied]
(When the actual soot accumulation is less than the displayed value)
Proceed to checks on cause 3 and after.
PC360LC-10 40-273
40 Troubleshooting

a When the actual soot accumulation is less than the displayed value
on the machine monitor
1. Proceed to checks on cause 4 to 7.
2. Turn the starting switch to the ON position, and perform the reset
after KDPF cleaning (see "Related information").
a Check that failure code [CA1922] is changed to [CA1921].
a If the failure code [CA1922] continues, check the resetting
procedure after KDPF cleaning, and perform the reset after KDPF
cleaning again.
Defective KDPF (KCSF) 5. Perform manual stationary regeneration from user mode.
3 (abnormal condition of soot
accumulation) a When the manual stationary regeneration is finished correctly, the
a If failure code [CA1922] is displayed again within 1 hour after
starting the manual stationary regeneration, perform Step 2 and 3
again.
a If failure code [CA1922], [CA1921] or [CA2639] is displayed after
manual stationary regeneration is completed, perform checks on
cause 8.
Defective KDOC inlet If failure code [CA3313], [CA3314], or [CA3315] is displayed, perform
4 temperature sensor troubleshooting for [CA3313], [CA3314], or [CA3315].
Defective KDOC outlet If failure code [CA3316], [CA3317], or [CA3318] is displayed, perform
5 temperature sensor troubleshooting for [CA3316], [CA3317], or [CA3318].
Defective KDPF outlet If failure code [CA3319], [CA3321] or [CA3322] is displayed, perform
6 temperature sensor troubleshooting for [CA3316], [CA3321] or [CA3322].
2. Monitor differential pressure sensed by KDPF differential pressure
sensor on monitoring screen of machine monitor.
Code 47,100 (kPa) 0 ± 3 (kPa)
a If the differential pressure is outside of the above range, perform the
Defective KDPF differential following.
7 pressure sensor
1. Remove KDPF differential pressure sensor tube.
(including sensor tubes) 2. Clean KDPF differential pressure sensor tube to clear clogging.
a If the KDPF differential pressure sensor tube is not clogged,
perform the following.
3. Perform for "Short circuit in wiring harness" of failure code [CA1881]
or [CA1883]. (If no short circuit occurs, replace the KDPF differential
pressure sensor.)
40-274 PC360LC-10
40 Troubleshooting

a If failure code [CA1921], or [CA2639] is displayed after manual
stationary regeneration is completed, perform following.
8 Unusual exhaust gas color then keep engine running at high idle for 5 seconds.
• If excessive black smoke is exhausted when accelerating engine or
running it at high idle, perform troubleshooting for "S-9 KDPF gets
clogged in a short time".
a When black smoke particles are exhausted during engine
acceleration, if it disappears with engine at high idle, the exhaust gas
color is judged as normal.
PC360LC-10 40-275
40 Troubleshooting
Failure code [CA1942] Crankcase Press Sens In Range Error (PC400-CA1942-400-A-

Z0-A)
Action level Failure code Crankcase Pressure Sensor In Range Error

Failure
Detail of • Output value from crankcase pressure sensor is out of normal range.
failure
controller
Problem on
machine
(Code: 48401 (V))
Defective crankcase pressure Crankcase pressure sensor system may be defective. Perform
sensor
2 Clogged KCCV filter Replace KCCV filter.
If error condition is not cleared after KCCV filter is replaced and
3 Blocked KCCV gas piping emulsion is found inside KCCV, emulsion may block KCCV blowby gas
piping. Perform troubleshooting for leakage of coolant.
If error condition is not cleared after KCCV filter is replaced and failure
code of crankcase pressure high error 2 is generated in short times,
4 Increase of blowby gas
engine may be seized or turbocharger may be defective. Perform
troubleshooting for mechanical system.
40-276 PC360LC-10
40 Troubleshooting
Failure code [CA1993] KDPF Delta Pressure Low Error (PC200LC_10-CA1993-400-A-Z0-A)
Action level Failure code KDPF Delta Pressure Low Error

Failure
Detail of • Signal voltage from KDPF delta pressure sensor is lower than threshold value.
failure
controller
machine
(Code: 47101 (V))
information • Temperature sensed by KDOC outlet temperature sensor can be checked with monitoring
O
Machine B. Machine operation for clearing failure code
operation for
clearing a This failure code does not disappear by simply turning starting switch to ON position from
failure code OFF position after repair. You must perform machine operation for clearing failure code
a In machine operation for clearing failure code, "dummy temperature sensor: 799T-601-
4680" is used.
PC360LC-10 40-277
40 Troubleshooting

Defective KDPF delta If failure code [CA1879], [CA1881], or [CA1883] is displayed, perform
1 pressure sensor troubleshooting for [CA1879], [CA1881], or [CA1883] first.
1. Turn starting switch to OFF position once, and then turn it to ON
position.
2. Check whether failure codes other than [CA1993] are generated.
3. Start engine and accelerate it suddenly from low idle to full speed
two times, then run it at full speed for 5 seconds. During above
operation, check exhaust gas color at exhaust pipe when engine
2 KCSF abnormality 1 accelerates suddenly and runs at full speed.
4. If black smoke is exhausted from exhaust pipe in above step 3,
KCSF is abnormal. Check whether KCSF is installed. If yes, check
KCSF for damage and foreign material in it, and fix trouble as
needed.
a If black smoke is not exhausted, proceed to checks on causes 3 and
after.
Perform following checks.
1. Check whether KDPF delta pressure sensor tube is installed.
2. Check whether KDPF delta pressure sensor tube is connected
Defective KDPF delta correctly.
3 pressure sensor tube 3. Remove KDPF delta pressure sensor tube and check it for clogging,
cracks, and damage.
4. Check both ends of KDPF delta pressure sensor tube for loose
connection.

2. Disconnect connector E26 and install dummy temperature sensor to female side.
5. After finishing warm-up operation, set swing lock switch to OFF position and working mode to P-mode.
6. Perform arm IN relief for continuous 1 minute.
a Take care not to overheat hydraulic oil.
a If failure code disappears after implementing steps 1 to 6, repair work is complete.
a If failure code still remains displayed, repeat above step 6 three times.
8. Remove dummy temperature sensor and restore connector connection.
command.
If this failure code is still displayed after above procedures are
implemented, remove KDPF and KCSF and check whether filter in
KCSF is installed. If yes, check filter for damage and foreign material in
4 KCSF abnormality 2 it, and fix trouble as needed.
After repair trouble, implement above "B. Machine operation for clearing
failure code".
40-278 PC360LC-10
40 Troubleshooting
PC360LC-10 40-279
40 Troubleshooting
Failure code [CA2185] Throt Sens Sup Volt High Error (PC300-CA2185-400-A-Z0-A)
Action level Failure code Throttle Sensor Supply Voltage High Error
Failure
Detail of • High voltage appears in throttle sensor power supply (5 V) circuit.
failure
detection.
machine
information
N- Procedure, measuring location, criteria and remarks
Cause
o.
equipment" in "Checks before troubleshooting" of "General information
Defective wiring harness on troubleshooting", and check it.
connector
If this failure code disappears, wiring harness connector is defective.
2. Disconnect connector P20, and turn starting switch to ON position.
Defective throttle sensor
2 (fuel control dial) If this failure code disappears, throttle sensor is defective.
a Other failure codes are also displayed. They are generated because of
disconnection of connector. Ignore failure codes other than [CA2185].
2. Disconnect connectors CE03 and P20, and connect T-adapter to
3 female side of CE03.
harness
Resis- Between CE03 (female) (42) and each pin other
Min. 100 kz
tance than pin CE03 (female) (42)
2. Disconnect connector P20, and connect T-adapter to female side.
Voltage Between P20 (female) (1) and ground 4.75 to 5.25 V
If no failure is found by above checks, engine controller is defective. (Since
this is an internal defect, troubleshooting cannot be performed.)
• Reference
2. Insert T-adapter into connector CE03.
Power
Voltage Between CE03 (42) and (41)
supply 4.75 to 5.25 V
40-280 PC360LC-10
40 Troubleshooting
PC360LC-10 40-281
40 Troubleshooting
Failure code [CA2186] Throt Sens Sup Volt Low Error (PC300-CA2186-400-A-Z0-A)
Action level Failure code Throttle Sensor Supply Voltage Low Error
Failure
Detail of • Low voltage appears in throttle sensor power supply (5 V) circuit.
failure
detection.
machine
information
N- Procedure, measuring location, criteria and remarks
Cause
o.
equipment" in "Checks before troubleshooting" of "General information
Defective wiring harness on troubleshooting", and check it.
connector
2. Disconnect connector P20, and turn starting switch to ON position.
Defective throttle sensor
2 (fuel control dial) If this failure code disappears, throttle sensor is defective.
a Other failure codes are also displayed. They are generated because of
disconnection of connector. Ignore failure codes other than [CA2186].
Ground fault in wiring 2. Disconnect connectors CE03 and P20, and connect T-adapter to either
3 harness female side.
(contact with ground circuit) Resis- Between ground and CE03 (female) (42) or P20
Min. 100 kz
tance (female) (1)
2. Disconnect connectors CE03 and P20, and connect T-adapter to
Short circuit in wiring female side of CE03.
harness
Resis- Between CE03 (female) (42) and each pin other
Min. 100 kz
tance than pin CE03 (female) (42)
If no failure is found by above checks, engine controller is defective. (Since
this is an internal defect, troubleshooting cannot be performed.)
• Reference
2. Insert T-adapter into connector CE03.
Power
Voltage Between CE03 (42) and (41)
supply 4.75 to 5.25 V
40-282 PC360LC-10
40 Troubleshooting
PC360LC-10 40-283
40 Troubleshooting
Failure code [CA2249] Rail Press Very Low Error (PC400-CA2249-400-A-Z0-A)
Action level Failure code Rail Pressure Very Low Error

Failure
Detail of • Supply pump does not feed fuel (level 2).
failure
Action of • Limits engine output (limits common rail pressure) and allows engine to run.
controller
machine
• Signal voltage from common rail pressure sensor can be checked by using monitoring
Related • Common rail pressure sensed by common rail pressure sensor can be checked with
information monitoring function. (Code: 36400 (MPa))
Supply pump pressure low Perform troubleshooting for failure code [CA559].
1
error
40-284 PC360LC-10
40 Troubleshooting
Failure code [CA2265] Fuel Feed Pump Open Error (D65-CA2265-400-A-Z0-A)
Action level Failure code Fuel feed pump open circuit error
Failure
Detail of • Open circuit is detected in the fuel feed pump drive signal circuit.
failure
controller
Problem on • Engine starting performance is poor
machine
information
1
defective.
Defective fuel feed pump 2. Disconnect connector FUEL LIFT PUMP.
2
(internal open circuit in wiring) Resis- Between FUEL LIFT PUMP (male) (1) and
(2) Max. 20 z
tance
3 of connector.
harness
Max. 20 z
tance
Open circuit in wiring harness 2. Disconnect connectors ECM J1 and FUEL LIFT PUMP and connect
4 (wire breakage or defective T-adapters to female side of each connector.
contact of connector) Between ECM J1 (female) (1) and FUEL
Max. 1 z
Resis- LIFT PUMP (1)
tance Between ECM J1 (female) (11) and FUEL
LIFT PUMP (2) Max. 1 z

2. Disconnect connectors ECM J1 and FUEL LIFT PUMP, and connect
T-adapter to female side of ECM J1.
Between ECM J1 (female) (1) and every pin No continuity
other than (1) (No sound is heard)
2. Disconnect connector FUEL LIFT PUMP.
3. Insert T-adapter in connector ECM J1 or connect to female side of
Hot short circuit in wiring connector FUEL LIFT PUMP.
6 harness 4. Turn starting switch to ON position (with connector FUEL LIFT
(contact with 24 V circuit) PUMP as connected) and start measurement after one minute.
a Average voltage is displayed because of PWM.
Between ECM J1 (1) and (11), or between
Voltage Max. 6 V
FUEL LIFT PUMP (female) (1) and (2)
PC360LC-10 40-285
40 Troubleshooting
Circuit diagram related to fuel feed pump
40-286 PC360LC-10
40 Troubleshooting
Failure code [CA2266] Fuel Feed Pump Short Error (D65-CA2266-400-A-Z0-A)
Action level Failure code Fuel feed pump short circuit error
Failure
Detail of • Short circuit is detected in fuel feed pump actuator drive circuit.
failure
controller
Problem on • Engine starting performance is poor.
machine
information
1
defective.
Defective fuel feed pump 2. Disconnect connector FUEL LIFT PUMP.
(internal open circuit in wiring)
If failure code changes from [CA2266] to [CA2265], fuel feed pump is
defective.
Open or short circuit in wiring of connector.
3
harness
Resis- Between ECM J1 (female) (1) and (11) 1 to 20 z
2. Disconnect connectors ECM J1 and FUEL LIFT PUMP, and connect
4 Short circuit in wiring harness T-adapter to female side of ECM J1 or FUEL LIFT PUMP.
Between ECM J1 (female) (1) and (11), or
Resis- between FUEL LIFT PUMP (female) (1) and
Min. 100 kz
tance (2)
Ground fault in wiring harness 2. Disconnect connectors ECM J1 and FUEL LIFT PUMP, and connect
5 T-adapter to female side of ECM J1 or FUEL LIFT PUMP.
Between ECM J1 (female) (1) and ground, or
Resis- between FUEL LIFT PUMP (female) (1) and
Min. 100 kz
tance ground
PC360LC-10 40-287
40 Troubleshooting
Circuit diagram related to fuel feed pump
40-288 PC360LC-10
40 Troubleshooting
Failure code [CA2271] EGR Valve Pos Sens High Error (D65-CA2271-400-A-Z0-A)
Action level Failure code EGR Valve Position Sensor High Error
Failure
Detail of • High voltage appears in signal circuit of EGR valve lift sensor.
failure
machine
• Signal voltage from EGR valve lift sensor can be checked with monitoring function.
(Code: 18101 (V))
Related • Position sensed by EGR valve lift sensor can be checked with monitoring function.
information (Code: 18100 (mm))
Defective sensor power If failure code [CA352] or [CA386] is displayed, perform troubleshooting
2 supply circuit for [CA352] or [CA386] first.
Defective EGR valve lift 2. Disconnect connector SEGR.
(internal defect) If failure code [CA2271] changes to [CA2272], EGR valve lift sensor is
defective.
2. Disconnect connector INTER-CONNECT.
If failure code [CA2271] changes to [CA2272], connector box is
Defective connector box
4 defective.
(internal short circuit)
a EGR solenoid failure code [CA2349], KVGT sensor failure code
[CA2382], and KVGT solenoid failure code [CA2383] are also
displayed. They are generated because of disconnection connector
INTER-CONNECT. Ignore these failure codes.
2. Disconnect connectors INTER-CONNECT and SEGR, and connect
Open circuit in connector box T-adapters to INTER-CONNECT male side and SEGR female side.
Resis- Between INTER-CONNECT (male) (4) and
SEGR (female) (B) Max. 10 z
tance
2. Disconnect connectors ECM J2 and INTER-CONNECT, and
Open circuit in wiring harness connect T-adapters to each female side.
6 (wire breakage or defective a To check open circuit in GND line
contact of connector) a If no failure is found by check on cause 2, this check is not required.
Resis- Between ECM J2 (female) (47) and INTER- Max. 10 z
tance CONNECT (female) (4)
PC360LC-10 40-289
40 Troubleshooting

Between ECM J2 (female) (30) and (59) or
Resis- between INTER-CONNECT (female) (3) and Min. 100
tance (5) kz

Hot short circuit in wiring 2. Disconnect connector SEGR and connect T-adapters to female side.
harness
Voltage Between SEGR (female) (C) and (B) Max. 1 V
• Reference
Sensor 1.0 to 4.0
output V
Circuit diagram related to EGR valve lift sensor
40-290 PC360LC-10
40 Troubleshooting
Failure code [CA2272] EGR Valve Pos Sens Low Error (D65-CA2272-400-A-Z0-A)
Action level Failure code EGR Valve Position Sensor Low Error
Failure
Detail of • Low voltage appears in signal circuit of EGR valve lift sensor.
failure
machine
• Signal voltage from EGR valve lift sensor can be checked with monitoring function.
(Code: 18101 (V))
Related • Position sensed by EGR valve lift sensor can be checked with monitoring function.
If failure code [CA352] or [CA386] is displayed, perform troubleshooting
for [CA352] or [CA386] first.
2 2. Disconnect connector SEGR and connect T-adapters to female side.
supply circuit
Between SEGR (female) (A) and Power 4.75 to 5.25
Voltage
(B) supply V
T-adapters to INTER-CONNECT male side and SEGR female side.
this check is not required. Between INTER- Max. 10 z
Open circuit in connector box CONNECT (male) (3) and SEGR (female)
3 (wire breakage or defective (A).
tance
this check is not required. Between INTER- Max. 10 z
CONNECT (male) (4) and SEGR (female)
(B).
Between INTER-CONNECT (male) (5) and
SEGR (female) (C) Max. 10 z

Ground fault in connector T-adapters to INTER-CONNECT male side and SEGR female side.
4 box Between ground and INTER-CONNECT
Min. 100 kz
(contact with ground circuit) Resis- (male) (5) or SEGR (female) (C)
tance Between ground and INTER-CONNECT
(male) (3) or SEGR (female) (A) Min. 100 kz
PC360LC-10 40-291
40 Troubleshooting

Short circuit in connector box T-adapters to INTER-CONNECT male side and SEGR female side.
5 Between INTER-CONNECT (male) (4) and
(internal short circuit) Min. 100 kz
Resis- (5), or between SEGR (female) (B) and (C)
tance Between INTER-CONNECT (male) (3) and
(4), or between SEGR (female) (A) and (B) Min. 100 kz

2. Disconnect connectors ECM J2 and INTER-CONNECT, and connect
T-adapters to each female side.
this check is not required.
Open circuit in wiring Max. 10 z
harness Between ECM J2 (female) (30) and
6 INTER-CONNECT (female) (3)
tance
this check is not required.
Max. 10 z
Between ECM J2 (female) (47) and
INTER-CONNECT (female) (4)
Between ECM J2 (female) (59) and INTER-
CONNECT (female) (5) Max. 10 z

2. Disconnect connectors ECM J2 and INTER-CONNECT, and connect
Ground fault in wiring T-adapters to each female side.
7 harness Between ground and ECM J2 (female) (59) or
Min. 100 kz
(contact with ground circuit) Resis- INTER-CONNECT (female) (5)
tance Between ground and ECM J2 (female) (30) or
INTER-CONNECT (female) (3) Min. 100 kz

2. Disconnect connectors ECM J2 or INTER-CONNECT, and connect
T-adapters to each female side.
Between ECM J2 (female) (47) and (59) or
8 between INTER-CONNECT (female) (4) and Min. 100 kz
harness
Resis- (5)
between INTER-CONNECT (female) (3) and Min. 100 kz
(4)
2. Insert T-adapters into connector SEGR.
Defective EGR valve lift
9 sensor a Sensor voltage is measured with wiring harness connected.
(internal defect) Accordingly, if voltage is abnormal, check harness connector for
failure, and then determine whether sensor is defective or not.
Sensor
Voltage Between SEGR (C) and (B) 1.0 to 4.0 V
output
10 Defective engine controller (Since this is an internal defect, troubleshooting cannot be performed.)
40-292 PC360LC-10
40 Troubleshooting
Circuit diagram related to EGR valve lift sensor
PC360LC-10 40-293
40 Troubleshooting
Failure code [CA2288] Turbo Speed High Error 1 (D65-CA2288-400-A-Z0-A)
Action level Failure code Turbocharger Speed High Error 1

Failure
Detail of • Turbocharger runs at abnormally high speed.
failure
controller
machine
• Speed sensed by turbocharger speed sensor can be checked with monitoring function.
Related (Code: 48100 (rpm))
Increased turbocharger
1 Turbocharger speed may increase abnormally high. Check it.
speed
If no failure is found by check on cause 1, turbocharger speed sensor
Defective turbocharger speed system may be defective. Perform troubleshooting for failure code
3
sensor [CA687].
40-294 PC360LC-10
40 Troubleshooting
Failure code [CA2311] IMV Solenoid Error (D65-CA2311-400-A-Z0-A)
Action level Failure code Defective IMV solenoid

Failure
Detail of • Resistance value of supply pump actuator circuit is unusually high or low. Or rail pressure
failure error.
controller
machine
information
1 Defective IMV solenoid Perform troubleshooting for failure codes [CA271] and [CA272].
2 Rail pressure error Perform troubleshooting for failure code [CA449].
PC360LC-10 40-295
40 Troubleshooting
Failure code [CA2349] EGR Valve Solenoid Open Error (D65-CA2349-400-A-Z0-A)
Action level Failure code EGR Valve Solenoid Open Error

Failure
Detail of • Open circuit is detected in EGR valve solenoid drive circuit.
failure
machine
• Signal current to EGR valve lift solenoid can be checked with monitoring function.
Related (Code: 48600 (mA))
1. See descriptions of wiring harness and connectors in "c:
Electrical equipment" in "Checks before troubleshooting" of
"General information on troubleshooting", and check it.
Defective EGR valve solenoid 2. Disconnect connector EGR-SOL and connect T-adapters to
2 male side.
Between EGR-SOL (male) (1) and
Resistance (2) 5 to 10 z

2. Disconnect connector ECM J2 and connect T-adapters to
Open circuit or short circuit in female side.
3 wiring harness a To measure resistance of EGR valve solenoid
Resistance (16) 5 to 10 z

2. Disconnect connectors ECM J2 and EGR-SOL, and connect
Ground fault in wiring harness T-adapters to either female side.
4
(contact with ground circuit) Between ground and ECM J2
Resistance (female) (6) or EGR-SOL (female) Min. 100 kz
(1)
a If no failure is found by check on cause 3, this check is not
required.
Open circuit in connector box 2. Disconnect connectors EGR-SOL and INTER-CONNECT,
5 (wire breakage or defective contact and connect T-adapters to INTER-CONNECT male side and
of connector) EGR-SOL female side.
Between INTER-CONNECT (male)
(1) and EGR-SOL (female) (1) Max. 10 z
Resistance
Between INTER-CONNECT (male)
(2) and EGR-SOL (female) (2) Max. 10 z

required.
Ground fault in connector box 2. Disconnect connectors EGR-SOL and INTER-CONNECT,
6 and connect T-adapters to INTER-CONNECT male side or
EGR-SOL female side.
Between ground and INTER-
Resistance CONNECT (male) (1) or EGR-SOL Min. 100 kz
(female) (1)
40-296 PC360LC-10
40 Troubleshooting

required.
Open circuit in wiring harness 2. Disconnect connectors ECM J2 and INTER-CONNECT, and
7 (wire breakage or defective contact connect T-adapters to each connector.
of connector) Between ECM J2 (female) (6) and
INTER-CONNECT (female) (1) Max. 10 z
Resistance
INTER-CONNECT (female) (2) Max. 10 z

required.
Ground fault in wiring harness 2. Disconnect connectors ECM J2 and INTER-CONNECT, and
8
(contact with ground circuit) connect T-adapters to each female side.
Between ground and ECM J2
Resistance (female) (6) or INTER-CONNECT Min. 100 kz
(female) (1)
2. Disconnect connectors ECM J2 and EGR-SOL, and connect
T-adapters to female side of ECM J2.
No continuity
Between EGR J2 (female) (6) and
each pin other than pin (6)
heard)
If no failure is found by above checks, engine controller is
10 Defective engine controller defective. (Since this is an internal defect, troubleshooting cannot
be performed.)
Circuit diagram related to EGR valve solenoid
PC360LC-10 40-297
40 Troubleshooting
Failure code [CA2353] EGR Valve Solenoid Short Error (D65-CA2353-400-A-Z0-A)
Action level Failure code EGR Valve Solenoid Short Error

Failure
Detail of
• Short circuit is detected in EGR valve solenoid drive circuit.
failure
machine
• Signal current to EGR valve lift solenoid can be checked with monitoring function.
Defective EGR valve 2. Disconnect connector EGR-SOL and connect T-adapters to male
2 solenoid side.
(internal short circuit) Resis- Between EGR-SOL (male) (1) and (2)
5 to 10 z
tance
Open or short circuit in wiring side.
3
harness a To measure resistance of EGR valve solenoid
5 to 10 z
tance
Ground fault in wiring 2. Disconnect connectors ECM J2 and EGR-SOL, and connect T-
4 harness adapters to either female side.
(contact with ground circuit) Resis- Between ground and ECM J2 (female) (6) or
EGR-SOL (female) (1) Min. 100 kz
tance
Ground fault in connector box 2. Disconnect connectors EGR-SOL and INTER-CONNECT, and
5 connect T-adapters to INRER-CONNECT male side and EGR-SOL
female side.
Resis- Between ground and INTER-CONNECT
(male) (1) or EGR-SOL (female) (1) Min. 100 kz
tance
6 harness 2. Disconnect connectors ECM J2 and INTER-CONNECT, and connect
(contact with ground circuit) T-adapters to each female side.
tance
40-298 PC360LC-10
40 Troubleshooting

2. Disconnect connectors ECM J2 and EGR-SOL, and connect T-
adapters to female side of ECM J2.

No
Between EGR J2 (female) (6) and each pin continuity
Continuity
other than pin (6) (No sound
is heard)
Circuit diagram related to EGR valve solenoid
PC360LC-10 40-299
40 Troubleshooting
Failure code [CA2357] EGR Valve Servo Error (D65-CA2357-400-A-Z0-A)
Action level Failure code EGR Valve Servo Error

Failure
Detail of • EGR valve servo error occurs.
failure (EGR lift sensor sends back EGR valve position value that differs from command value.)
Action of • Does not supply current to EGR valve (closes EGR valve).
machine
• Position of EGR valve can be checked with monitoring function. (Code: 18100 EGR Valve
Related Position (mm))
Defective relevant system If other failure codes are also displayed, perform troubleshooting for
1
them.
a For testing of EGR valve drive pressure, see Testing and adjusting,
Insufficient EGR valve drive "Measuring EGR valve and KVGT oil pressure".
2 pressure
If EGR valve drive pressure is abnormal, perform checks on causes 3
and 4.
a For check of engine oil pressure, see Testing and adjusting, "Testing
Defective engine oil pressure engine oil pressure".
3 system (main circuit) If engine oil pressure is not normal, perform troubleshooting (S mode)
for mechanical system. (S-14 Engine oil pressure drops)
Defective oil pump for EGR Oil pump or relief valve for EGR valve circuit may be defective. Check
4
valve them.
Defective hydraulic piping for Hydraulic piping of EGR valve circuit may be defective. Check it.
5
EGR valve
Defective return hydraulic
6 Return hydraulic piping for EGR valve circuit may be defective. Check it.
piping for EGR valve
7 Defective EGR valve EGR valve may have mechanical trouble. Check it.
Defective EGR valve lift Perform troubleshooting for failure codes [CA2271] and [CA2272].
8
sensor
If no failure is found by checks on causes 1 to 8, engine controller is
40-300 PC360LC-10
40 Troubleshooting
Failure code [CA2373] Exhaust Manifold Press Sens High error (D65-CA2373-400-
A-Z0-A)
Action level Failure code Exhaust Manifold Pressure Sensor High Error
Failure
Detail of • High voltage appears in signal circuit of exhaust manifold pressure sensor.
failure
• Takes it that exhaust manifold pressure is at calculated value and allows engine to run.
machine
• Signal voltage from exhaust manifold pressure sensor can be checked with monitoring
function.
(Code: 48301 (V))
Related • Pressure sensed by exhaust manifold pressure sensor can be checked with monitoring
(Code: 48300 (MPa))
Defective boost pressure 2. Disconnect connector EXHAUST PRESSURE.
(internal defect) If failure code [[CA2373] changes to [CA2374], exhaust manifold
pressure sensor is defective.
Short circuit in wiring harness 2. Disconnect connectors ECM J2 and EXHAUST PRESSURE, and
4 (Short circuit between wiring connect T-adapters to each female side.
harnesses) Resis- Between ECM J2 (34) and (30), or between Min. 100
tance EXHAUST PRESSURE (female) (3) and (1) kz
2. Disconnect connector EXHAUST PRESSURE and connect T-
Hot short circuit in wiring adapters to female side.
harness
Between EXHAUST PRESSURE (female) (3)
Voltage Max. 1 V
and (2)
• Reference
Sensor 0.2 to 4.7
output V
PC360LC-10 40-301
40 Troubleshooting
Circuit diagram related to exhaust manifold pressure sensor
40-302 PC360LC-10
40 Troubleshooting
Failure code [CA2374] Exhaust Manifold Press Sens Low error (D65-CA2374-400-
A-Z0-A)
Action level Failure code Exhaust Manifold Pressure Sensor Low Error
Failure
Detail of • Low voltage appears in signal circuit of exhaust manifold pressure sensor.
failure
machine
function.
(Code: 48301 (V))
(Code: 48300 (MPa))
Defective sensor power 2. Disconnect connector EXHAUST PRESSURE and connect T-
2 supply circuit adapters to female side.
Between EXHAUST PRESSURE Power 4.75 to 5.25
Voltage
(female) (1) and (2) supply V
2. Disconnect connectors ECM J2 and EXHAUST PRESSURE, and
connect T-adapters to each female side.
Open circuit in wiring harness Between ECM J2 (30) and EXHAUST
PRESSURE (female) (1) Max. 10 z
contact of connector) Resis- Between ECM J2 (female) (47) and EXHAUST
tance
Between ECM J2 (female) (34) and EXHAUST

2. Disconnect connectors ECM J2 and EXHAUST PRESSURE, and
Ground fault in wiring connect T-adapters to either female side.
4 harness Between ground and ECM J2 (female) (34) or
Min. 100 kz
(contact with ground circuit) Resis- EXHAUST PRESSURE (female) (3)
tance Between ground and ECM J2 (female) (30) or
EXHAUST PRESSURE (female) (1) Min. 100 kz

Short circuit in wiring harness 2. Disconnect connectors ECM J2 and EXHAUST PRESSURE, and
5 (Short circuit between wiring connect T-adapters to either female side.
harnesses) Resis- Between ECM J2 (34) and (47), or between Min. 100 z
tance EXHAUST PRESSURE (female) (2) and (3)
PC360LC-10 40-303
40 Troubleshooting

Defective exhaust manifold 2. Insert T-adapter to connector ECM J2
(internal defect) Between EXHAUST PRESSURE (female) (3)
and (2)
Circuit diagram related to exhaust manifold pressure sensor
40-304 PC360LC-10
40 Troubleshooting
Failure code [CA2375] EGR Orifice Temp Sens High Error (D65-CA2375-400-A-Z0-A)
Action level Failure code EGR Orifice Temperature Sensor High Error
Failure
Detail of • High voltage appears in signal circuit of EGR orifice temperature sensor.
failure
• Runs engine by setting EGR orifice temperature to calculated value.
machine
• Signal voltage from EGR orifice temperature sensor can be checked with monitoring
function.
(Code: 48501 (V))
Related • Temperature sensed by EGR orifice temperature sensor can be checked with monitoring
(Code: 48500 (°C))
2. Disconnect connector EXHAUST GAS TEMPERATURE and
connect T-adapters to male side.
760 to 880
-30 °C
kz
380 to 515
0 °C
kz
155 to 225
25 °C
kz
Defective EGR orifice
Between EXHAUST GAS 21 to 29
2 temperature sensor (internal 80 °C
defect) TEMPERATURE (male) (1) and (2) kz
Resis- 900 to
tance 200 °C
1050 z
150 to 200
300 °C
z
400 °C 40 to 56 z
500 °C 15 to 22 z
Between EXHAUST GAS
Whole Min. 100
TEMPERATURE (male) (2) and
range kz
ground (sensor body)
Open or short circuit in wiring 2. Disconnect connector ECM J2 and connect T-adapters to female
harness side.
3 (short circuit, wire breakage a Use Temperature-Resistance characteristics table of EGR orifice
or defective contact of temperature sensor that is used for check on cause 2 as resistance
connector) criteria.
Resis- Between ECM J2 (female) (18) and (48) 15 z to
tance 880 kz
PC360LC-10 40-305
40 Troubleshooting

Hot short circuit in wiring connect T-adapters to female side.
harness
Between EXHAUST GAS TEMPERATURE Max. 5.25
Voltage
(female) (1) and (2) V
Circuit diagram related to EGR orifice temperature sensor
40-306 PC360LC-10
40 Troubleshooting
Failure code [CA2376] EGR Orifice Temp Sens Low Error (D65-CA2376-400-A-Z0-A)
Action level Failure code EGR Orifice Temperature Sensor Low Error
Failure
Detail of • Low voltage appears in signal circuit of EGR orifice temperature sensor.
failure
• Runs engine by setting EGR orifice temperature to calculated value.
machine
function.
(Code: 48501 (V))
(Code: 48500 (°C))
Defective EGR orifice 2. Disconnect connector EXHAUST GAS TEMPERATURE.
2 temperature sensor (internal 3. Turn starting switch to ON position.
defect) If this failure code changes to [CA2375], EGR orifice temperature
• Reference
connect T-adapters to male side.
760 to 880
-30 °C
kz
380 to 515
0 °C
kz
155 to 225
25 °C
Defective EGR orifice kz
3 temperature sensor (internal Between EXHAUST GAS 21 to 29
80 °C
defect) TEMPERATURE (male) (1) and (2) kz
Resis- 900 to
tance 200 °C
1050 z
150 to 200
300 °C
z
400 °C 40 to 56 z
500 °C 15 to 22 z
Between EXHAUST GAS
Whole Min. 100
TEMPERATURE (male) (2) and
range kz
ground (sensor body)
PC360LC-10 40-307
40 Troubleshooting

Open or short circuit in wiring 2. Disconnect connector ECM J2 and connect T-adapters to female
harness side.
4 (Short circuit, open circuit or a Use Temperature-Resistance characteristics table of EGR orifice
defective contact of temperature sensor that is used for check on cause 2 as resistance
connector) criteria.
Resis- Between ECM J2 (female) (18) and (48) 15 z to
tance 880 kz
Ground fault in wiring harness 2. Disconnect connectors ECM J2 and EXHAUST GAS
5 TEMPERATURE, and connect T-adapters to either female side.
Resis- Between ground and ECM J2 (female) (48) or Min. 100
tance EXHAUST GAS TEMPERATURE (female) (2) kz
Circuit diagram related to EGR orifice temperature sensor
40-308 PC360LC-10
40 Troubleshooting
Failure code [CA2381] KVGT Pos Sens High Error (D65-CA2381-400-A-Z0-A)
Action level Failure code KVGT Position Sensor High Error

Failure
Detail of • High voltage appears in signal circuit of KVGT position sensor.
failure
• Closes EGR valve and opens KVGT fully.
machine
• Signal voltage from KVGT position sensor can be checked with monitoring function.
(Code: 48701 (V))
Related • Position sensed by KVGT position sensor can be checked with monitoring function.
Defective KVGT position 2. Disconnect connector SVGT.
(internal defect) a If failure code [CA2381] changes to [CA2382], KVGT position sensor
is defective.
2. Disconnect connector INTER-CONNECT.
If failure code [CA2381] changes to [CA2382], connector box is
Defective connector box defective.
4
(internal short circuit) a EGR solenoid failure code [CA2349], EGR sensor failure code
[CA2272], and KVGT solenoid failure code [CA2383] are also
displayed.
Ignore these failure codes since they are generated because of
disconnection of connector INTER-CONNECT.
2. Disconnect connectors INTER-CONNECT and SVGT and connect T-
Open circuit in connector box adapters to INTER-CONNECT male side and SVGT female side.
SVGT (female) (B) Max. 10 z
tance
Open circuit in wiring harness 2. Disconnect connectors ECM J2 and INTER-CONNECT, and
Resis- Between ECM J2 (female) (47) and INTER-
tance
PC360LC-10 40-309
40 Troubleshooting

Short circuit in wiring harness 2. Disconnect connectors ECM J2 and INTER-CONNECT, and
7 (Short circuit between wiring
harnesses) Between ECM J2 (female) (30) and (38) or
Resis- between INTER-CONNECT (female) (8) and Min. 100
tance (10) kz

Hot short circuit in wiring 2. Disconnect connector SVGT and connect T-adapters to female side.
harness
Voltage Between SVGT (female) (C) and (B) Max. 1 V
• Reference
Sensor 1.0 to 4.0
output V
Circuit diagram related to KVGT position sensor
40-310 PC360LC-10
40 Troubleshooting
Failure code [CA2382] KVGT Pos Sens Low Error (D65-CA2382-400-A-Z0-A)
Action level Failure code KVGT Position Sensor Low Error

Failure
Detail of • Low voltage appears in signal circuit of KVGT position sensor.
failure
machine
• Signal voltage from KVGT position sensor can be checked with monitoring function.
(Code: 48701 (V))
Related • Position sensed by KVGT position sensor can be checked with monitoring function.

2 supply circuit 2. Disconnect connector SVGT and connect T-adapters to female side.
Between SVGT (female) (A) and Power 4.75 to
Voltage
(B) supply 5.25 V
2. Disconnect connectors INTER-CONNECT and SVGT, and connect
Open circuit in connector box T-adapters to INRER-CONNECT male side and SVGT female side.
3 (wire breakage or defective Between INTER-CONNECT (male) (8) and
SVGT (female) (A) Max. 10 z
SVGT (female) (B) Max. 10 z
tance
Between INTER-CONNECT (male) (10) and
SVGT (female) (C) Max. 10 z

2. Disconnect connectors INTER-CONNECT and SVGT, and connect
Ground fault in connector box T-adapters to INRER-CONNECT male side or SVGT female side.
4 Between ground and INTER-CONNECT (male) Min. 100
Resis- (10) or SVGT (female) (C) kz
tance Between ground and INTER-CONNECT (male) Min. 100
(8) or SVGT (female) (A) kz
PC360LC-10 40-311
40 Troubleshooting

2. Disconnect connectors INTER-CONNECT and SVGT,and connect
Short circuit in connector box T-adapters to INRER-CONNECT male side or SVGT female side.
5 Between INTER-CONNECT (male) (9) and Min. 100
Resis- (10), or between SVGT (female) (B) and (C) kz
tance Between INTER-CONNECT (male) (8) and (9), Min. 100
or between SVGT (female) (A) and (B) kz
Open circuit in wiring harness connect T-adapters to each female side.
6 (wire breakage or defective Between ECM J2 (female) (30) and INTER-
Resis- Between ECM J2 (female) (47) and INTER-
tance
Between ECM J2 (female) (38) and INTER-

Ground fault in wiring harness connect T-adapters to each female side.
7 Between ground and ECM J2 (female) (38) or Min. 100
Resis- INTER-CONNECT (female) (10) kz
tance Between ground and ECM J2 (female) (30) or Min. 100
INTER-CONNECT (female) (8) kz
Short circuit in wiring harness Between ECM J2 (female) (47) and (38) or
8 (Short circuit between wiring between INTER-CONNECT (female) (9) and Min. 100
kz
harnesses) Resis- (10)
between INTER-CONNECT (female) (8) and Min. 100
(9) kz

2. Insert T-adapters into connector SVGT.
Defective KVGT position
9 sensor a Sensor voltage is measured with wiring harness connected.
(internal defect) Accordingly, if voltage is abnormal, check harness connector for
failure, and then determine whether sensor is defective or not.
Sensor 1.0 to 4.0
Voltage Between SVGT (C) and (B)
output V
40-312 PC360LC-10
40 Troubleshooting
Circuit diagram related to KVGT position sensor
PC360LC-10 40-313
40 Troubleshooting
Failure code [CA2383] KVGT Solenoid Open Error (D65-CA2383-400-A-Z0-A)
Action level Failure code KVGT Solenoid Open Error

Failure
Detail of • Open circuit is detected in KVGT solenoid drive circuit.
failure
machine
• Signal current to KVGT solenoid can be checked with monitoring function. (Code: 48800
Related (mA))
Defective KVGT solenoid 2. Disconnect connector VGT-SOL and connect T-adapters to male
2 side.
Resis- Between VGT-SOL (male) (1) and (2)
5 to 10 z
tance
3
harness a To measure resistance of KVGT valve solenoid
5 to 10 z
tance
Ground fault in wiring 2. Disconnect connectors ECM J2 and VGT-SOL, and connect T-
VGT-SOL (female) (1) Min. 100 kz
tance
2. Disconnect connectors VGT-SOL and INTER-CONNECT, and
Open circuit in connector box connect T-adapters to INRER-CONNECT male side and VGT-SOL
5 (wire breakage or defective female side.
contact of connector) Between INTER-CONNECT (male) (6) and
Max. 10 z
Resis- VGT-SOL (female) (1)
tance Between INTER-CONNECT (male) (7) and
VGT-SOL (female) (2) Max. 10 z

Ground fault in connector box 2. Disconnect connectors VGT-SOL and INTER-CONNECT, and
6 connect T-adapters to INRER-CONNECT male side or VGT-SOL
female side.
Resis- Between INTER-CONNECT (male) (6) or VGT-
SOL (female) (1), and ground. Min. 100 kz
tance
40-314 PC360LC-10
40 Troubleshooting

Open circuit in wiring harness 2. Disconnect connectors ECM J2 and INTER-CONNECT, and connect
7 (wire breakage or defective T-adapters to each female side.
contact of connector) Between ECM J2 (female) (10) and INTER-
Max. 10 z
Resis- CONNECT (female) (6)
tance Between ECM J2 (female) (20) and INTER-

tance
2. Disconnect connectors ECM J2 and VGT-SOL, and connect T-

No
Between ECM J2 (female) (10) and each pin continuity
Continuity
is heard)
Circuit diagram related to KVGT solenoid
PC360LC-10 40-315
40 Troubleshooting
Failure code [CA2386] KVGT Solenoid Short Error (D65-CA2386-400-A-Z0-A)
Action level Failure code KVGT Solenoid Short Error

Failure
Detail of
• Short circuit is detected in KVGT solenoid drive circuit.
failure
machine
• Signal current to KVGT solenoid can be checked with monitoring function.
Defective KVGT solenoid 2. Disconnect connector VGT-SOL and connect T-adapters to male
2 side.
Resis- Between VGT-SOL (male) (1) and (2)
5 to 10 z
tance
3
harness a To measure resistance of KVGT valve solenoid
5 to 10 z
tance
Ground fault in wiring 2. Disconnect connectors ECM J2 and VGT-SOL, and connect T-
VGT-SOL (female) (1) Min. 100 kz
tance
Ground fault in connector box 2. Disconnect connectors VGT-SOL and INTER-CONNECT, and
5 connect T-adapters to INTER-CONNECT male side or VGT-SOL
female side.
Resis- Between INTER-CONNECT (male) (6) or VGT-
SOL (female) (1), and ground. Min. 100 kz
tance
tance
40-316 PC360LC-10
40 Troubleshooting

2. Disconnect connectors ECM J2 and VGT-SOL, and connect T-

No
Between ECM J2 (female) (10) and each pin continuity
Continuity
is heard)
Circuit diagram related to KVGT solenoid
PC360LC-10 40-317
40 Troubleshooting
Failure code [CA2387] KVGT Servo Error (WA380_7-CA2387-400-A-Z0-A)
Action level Failure code KVGT Servo Error

Failure
• KVGT servo error occurs.
Detail of failure (KVGT position sensor sends back KVGT position value that differs from command
value.)
machine
information
1
them.
For testing of KVGT drive pressure, see Testing and adjusting,
Insufficient KVGT drive "Measuring EGR valve and KVGT oil pressure".
2 pressure a If KVGT drive pressure is abnormal, perform checks on causes 4
and 5.
For testing of KVGT control pressure, see Testing and adjusting,
Insufficient KVGT control "Testing EGR valve and KVGT oil pressure".
3 pressure
a If KVGT control pressure is abnormal, replace EPC valve for KVGT.
For check of engine oil pressure, see Testing and adjusting, "Testing
Defective engine oil pressure engine oil pressure".
4 system (main circuit)
If engine oil pressure is abnormal, perform troubleshooting (S mode) for
mechanical system. (S-14 Engine oil pressure lowers.)
5 Defective oil pump for KVGT Oil pump or relief valve for KVGT circuit may be defective. Check them.
Defective hydraulic piping for Hydraulic piping of KVGT circuit may be defective. Check it.
6
KVGT
Defective return hydraulic
7 piping for KVGT Return hydraulic piping of KVGT circuit may be defective. Check it.
KVGT may have mechanical failure. Check it.
If values of KDOC inlet temperature: approximately 250°C or below and
KVGT solenoid current: approximately 1000 mA remain unchanged
8 Defective KVGT after performing regeneration for service, KVGT is defective.
(Since the time required for manual stationary regeneration depends on
the accumulated soot level, see failure code CA2639. )
Defective KVGT position Perform troubleshooting for failure codes [CA2381] and [CA2382].
9
sensor
40-318 PC360LC-10
40 Troubleshooting
Failure code [CA2554] Exh Manifold Press Sens In Range Error (D65-CA2554-400-
A-Z0-A)
Action level Failure code Exhaust Manifold Pressure Sensor In Range Error
Failure
Detail of • Signal voltage output from exhaust manifold pressure sensor is out of normal range.
failure
machine
function.
(Code: 48301 (V))
(Code: 48300 (MPa))
• Method of reproducing failure code: Turn starting switch to ON position, or start engine
and run engine at high idle.
Blocked piping of exhaust Exhaust manifold pressure sensor piping may be blocked. Check piping
1 manifold pressure sensor for clogging.
Defective exhaust manifold Exhaust manifold pressure sensor system may be defective. Perform
2 pressure sensor troubleshooting for failure codes [CA2373] and [CA2374].
PC360LC-10 40-319
40 Troubleshooting
Failure code [CA2555] Grid Htr Relay Open Circuit Error (PC300-CA2555-400-A-Z0-A)
Action level Failure code Intake air heater relay open circuit
Failure
Detail of • Open circuit is detected in drive circuit (primary circuit) of preheat relay.
failure
controller
Problem on • Intake air heater does not work in auto preheating (degraded starting performance at low
machine temperature and emission of white smokes)
• Temperature sensed by boost temperature sensor can be checked with monitoring
function.
(Code: 18500 Boost temperature)
• Method of reproducing failure code: Turn starting switch to ON position (charge
temperature: lower than -4°C).
Related • Troubleshooting for this failure code covers circuit starting from engine controller to
information primary (coil) side of preheater relay R18.
• For troubleshooting related to heater relay and secondary side of preheater relay R18,
see E-mode below.
• E-2 Manual preheating system does not work
• E-3 Automatic preheating system does not work
• E-4 Preheating monitor does not light up when preheater is operated
1
defective.
2. Disconnect relay R18, and connect T-adapters to male side.
Resis- Between R18 (male) (1) and (2)
200 to 400 z
tance
2 Defective preheat relay
2. Replace relay R18 with another one.
If this failure code disappears, original preheater relay R18 is defective.
Open or short circuit in wiring 2. Disconnect connector CE03, and connect T-adapters to female side.
3
harness Resis- Between CE03 (female) (4) and (13)
200 to 400 z
tance a Preheater relay R18 coil resistance
2. Disconnect connector CE03 and relay R18, and connect T-adapters
4 Open circuit in wiring harness to each female side.
Between CE03 (female) (4) and R18 (female)
Max. 10 z
Resis- (1)
tance Between CE03 (female) (13) and R18
40-320 PC360LC-10
40 Troubleshooting
Circuit diagram related to intake air heater relay
PC360LC-10 40-321
40 Troubleshooting
Failure code [CA2556] Grid Htr Relay Short Circuit Error (PC300-CA2556-400-A-Z0-A)
Action level Failure code Intake air heater relay short circuit
Failure
Detail of • Short circuit is detected in drive circuit (primary circuit) of preheater relay.
failure
controller
Problem on • Intake air heater does not work in auto preheating (degraded starting performance at low
machine temperature and emission of white smokes)
• Temperature sensed by boost temperature sensor can be checked with monitoring
function.
(Code: 18500 Boost temperature)
• Method of reproducing failure code: Turn starting switch to ON position (charge
temperature: lower than -4°C).
Related • Troubleshooting for this failure code covers circuit starting from engine controller to
information primary (coil) side of preheater relay R18.
• For troubleshooting related to heater relay and secondary side of preheater relay R18,
see E-mode below.
• E-2 Manual preheating system does not work
• E-3 Automatic preheating system does not work
• E-4 Preheating monitor does not light up when preheater is operated
1
defective.
Resis- Between R18 (male) (1) and (2) 200 to 400
tance z
2 Defective preheat relay
2. Replace relay R18 with another one.
If this failure code disappears, original preheater relay R18 is defective.
3 Ground fault in wiring harness to either female side.
Resis- Between ground and CE03 (female) (4) or
R18 (female) (1) Min. 100 kz
tance
to female side of CE03.

No
Between CE03 (female) (4) and each pin other continuity
Continuity
than pin (4) (No sound
is heard)
40-322 PC360LC-10
40 Troubleshooting
Circuit diagram related to intake air heater relay
PC360LC-10 40-323
40 Troubleshooting
Failure code [CA2637] KDOC Face Plugging (PC200LC_10-CA2637-400-A-Z0-A)
Action level Failure code KDOC Face Plugging

Failure
• KDOC face is plugged.
1. The KDOC surface is contaminated due to the operating conditions, and the catalytic
Detail of efficiency has dropped (clean the DOC).
failure 2. Deteriorated KDOC due to high temperature, dropped efficiency due to deposit, or
dropped efficiency due to damage (Replace KDOC with a new or used one.)
Action of • Closes EGR valve
controller • Stops fuel dosing.
Problem on • None in particular
machine
k Since temperature of the turbocharger exhaust connector, KDOC and KDPF

exceeds 500 °C, take care not to get burn injury.
a When KDOC in KDPF is changed, perform reset procedure for KDOC change and then
finish repair.
• Procedure of performing manual stationary regeneration from Regeneration for Service.
performed only from "Regeneration for Service".
Related 1. Start the engine.
information 2. Make sure that machine is in safe condition.
3. From service menu of machine monitor, display the "Diagnostic Tests" screen, open
"02 Regeneration for service", and then perform the "Manual Stationary
Regeneration".
• If the KDOC efficiency is still low, this failure code [CA2637] may be displayed repeatedly
and failure code [CA1691] indicating the poor regeneration may be displayed.
<How to clear failure code>
• Start the engine and perform the warm-up operation, then operate the machine under
normal conditions for approximately 3 hours.
(If the exhaust gas temperature is high, this operation time can be reduced.)
1 Defective KVGT If failure code [CA238*] is displayed, troubleshoot for it first.
If failure code [CA227*], [CA23**] or others is displayed, troubleshoot for
2 Defective EGR valve
it first.
1. Remove turbocharger exhaust connector.
Defective turbocharger 2. Check for oil or fuel inside turbocharger exhaust connector.
3
exhaust connector • If contaminated, troubleshoot for failure codes [CA227*], [CA23**],
etc., relating to the EGR valve and KVGT.
Defective exhaust connector Check exhaust system between turbocharger and KDPF for damage of
4 and ducts connected to the connector and ducts, and for loose connection.
KDPF
then keep engine running at high idle for 5 seconds.
• If excessive black smoke is exhausted when running the engine at
high idle, troubleshoot for "S-9 KDPF gets clogged in a short time".
5 Unusual exhaust gas color
a It does not matter that black smoke particles are exhausted during
engine acceleration but are not exhausted during running at high
idle.
40-324 PC360LC-10
40 Troubleshooting

1. Remove KDPF.
2. Remove KDOC.
• Check KDOC for cracks (replace KDOC if cracks are found).
• Check whether more than 50% of KDOC inlet surface is plugged with
6 Defective KDOC soot or not.
(KDOC cleaning)
a When KDOC is replaced, perform check on cause 7. And when
cleaning of KDOC is done, perform checks on causes 7 and 8.
1. Install KDOC and KDPF.
3. From service menu of machine monitor, display the "Diagnostic
Tests" screen, open "03 KDPF Memory Reset", and then perform "03
KDOC Change" (reset after KDOC change).
7 Reset after KDOC change
a Check that reset after KDOC change is completed successfully (by
reset count). If not, perform troubleshooting again.
a When KDOC is replaced, finish troubleshooting without performing
manual stationary regeneration.
1. Perform manual stationary regeneration from Regeneration for
Service.
3. Repeat the "Regeneration for service" (to check the repair
Performing manual stationery completion).
8 regeneration
a If failure code [CA2637] is displayed after you have completed the
"Regeneration for Service", the KDOC efficiency has dropped.
Replace the KDOC and perform reset after KDOC change (see
Cause 7).
a Operate the machine approximately 3 hours and check that this failure code is not displayed.
PC360LC-10 40-325
40 Troubleshooting
Failure code [CA2639] Manual Stationary Regeneration Request (PC200LC_10-

CA2639-400-A-Z0-A)
Action level Failure code Manual Stationary Regeneration Request

Failure
The "Manual Stationary Regeneration Request" prompts operator to forcibly perform the
Detail of "Manual Stationary Regeneration", which is more effective to remove soot, because soot
failure accumulation in the KCSF of KDPF has exceeded level for the automatic regeneration.
• Soot accumulation reaches level 4 or 5.
Action of
• Normal control
controller
machine
injury.
• KVGT solenoid current can be checked with monitoring function. (Code: 48800 (mA))
Related engine is at idle (KDPF regeneration is not executed) are approximately 100 to 250°C,
information and difference between these temperatures is approximately 10°C. (KDOC inlet
inlet temperature is approximately 250 to 400°C, and KDOC outlet temperature and KDPF
outlet temperature are approximately 450 to 550°C.
• How to perform the manual stationary regeneration
3. From the service menu of the machine monitor, display the "Diagnostic Tests" screen,
open "Regeneration for Service", and perform the "Manual Stationary Regeneration".
a While the regeneration for service is in progress, the “monitoring” screen is displayed by
performing the switch operation: keep pressing numeral input switch [4] and sequentially
press [1], [2], and [3] in order.
(For detail, see Testing and adjusting “Regeneration for service ” . )
40-326 PC360LC-10
40 Troubleshooting
• If soot accumulation is level 4: Approximately 40 minutes to 1 hour
• If soot accumulation is level 5: Approximately 1 to 2 hours
• If soot accumulation is level 6 or 7: Approximately 1 to 3 hours
Related • If soot accumulation is level 8: The manual stationary regeneration can not be performed.
information
a If this failure code is still displayed after several hours have passed after the manual
stationary regeneration, perform the following troubleshooting procedures.
a If another failure code is displayed (including when the manual stationary regeneration is
in progress), perform troubleshooting for it first.
machine monitor.
If the regeneration stop button is pressed down, release it.
Increase of soot 3. Make sure that machine is in safe condition.
1 accumulation due to 4. Start the engine, and perform the manual stationary regeneration
"Regeneration Disable" from user mode.
a If the regeneration does not complete within 3 hours, proceed to
checks on cause 2 and after.
• If there is a significant difference between KDOC inlet temperature
Defective KDOC inlet and KDOC outlet temperature when KDPF is completely cool or
2 temperature sensor engine running at idle (not regenerating), replace KDOC inlet
temperature sensor.
KVGT may have mechanical failure. Check it.
If values of KDOC inlet temperature: approximately 250°C or below and
KVGT solenoid current: approximately 1000 mA remain unchanged after
3 Defective KVGT performing regeneration for service, KVGT is defective.
(The time required for the manual stationary regeneration depends on
the accumulated soot level. See "Related information".)
Defective KDPF (KDOC, 1. Perform the troubleshooting "S-22 Active regeneration takes time" of
4 KCSF) S mode.
a If failure code [CA2639] is displayed after the manual stationary
regeneration is completed, perform the following.
then keep engine running at high idle for 5 seconds.
5 Unusual exhaust gas color • If excessive black smoke is exhausted when accelerating engine or
running it at high idle, troubleshoot for "S-9 KDPF gets clogged in a
short time".
a When black smoke particles are exhausted during engine
acceleration, if it disappears with engine at high idle, the exhaust gas
color is judged as normal.
PC360LC-10 40-327
40 Troubleshooting

40-328 PC360LC-10
40 Troubleshooting
Failure code [CA2961] EGR Orifice Temp High Error 1 (D65-CA2961-400-A-Z0-A)
Action level Failure code EGR Orifice Temperature High Error 1

Failure
Detail of • Output signal from EGR orifice temperature sensor exceeds upper control limit or it
failure indicates value out of normal range.
controller
machine
function.
(Code: 48501(V))
(Code: 48500 (°C))
1
them.
Increasing of EGR gas EGR gas temperature may rise excessively. Perform troubleshooting for
2 temperature it.
Defective EGR orifice EGR orifice temperature sensor system may be defective. Perform
3 temperature sensor troubleshooting for failure codes [CA2375] and [CA2376].
PC360LC-10 40-329
40 Troubleshooting
Failure code [CA2973] Chg Air Press Sensor In Range Error (D65-CA2973-400-A-Z0-A)
Action level Failure code Charge Air Pressure Sensor In Range Error
Failure
Detail of • Output signal from charge (boost) pressure sensor is out of normal range.
failure
machine
• Signal voltage from boost pressure sensor can be checked with monitoring function.
(Code: 36501 (V))
Related • Pressure sensed by boost pressure sensor can be checked with monitoring function.
Defective boost pressure Boost pressure sensor system may be defective. Perform
sensor
40-330 PC360LC-10
40 Troubleshooting
Failure code [CA3133] KDPF Outlet Press Sens High Error (PC200LC_10-CA3133-400-A-
Z0-A)
Action level Failure code KDPF Outlet Pressure Sensor High Error
Failure
Detail of • High voltage appears in signal circuit of KDPF outlet pressure sensor.
failure
• Takes it that KDPF delta pressure is at estimated value (gauge pressure) and allows
Action of engine to run.
controller (Controller may use 0 kPa (gauge pressure) to run engine if another failure code is also
displayed.)
Problem on
• None
machine
• If failure code [CA1695] is not displayed but failure code [CA1879] is on screen, GND
Related circuit probably has open circuit (defective contact of connector).
information • Signal voltage from KDPF outlet pressure sensor can be checked with monitoring
• Delta pressure sensed by KDPF outlet pressure sensor can be checked with monitoring

connector
Defective KDPF outlet If this failure code changes to [CA3134], KDPF outlet pressure sensor is
3 pressure sensor defective.
a If this failure code remains displayed, wiring harness or engine
harness 2. Disconnect connectors CE03 and E25, and connect T-adapter to
4 each female side.
Resis- Between CE03 (female) (43) and E25 Max. 10 z
tance (female) (1)
PC360LC-10 40-331
40 Troubleshooting

harness
No continuity
Between CE03 (female) (58) and each pin
other than pin (58)
heard)
Circuit diagram related to KDPF outlet pressure sensor
40-332 PC360LC-10
40 Troubleshooting
Failure code [CA3134] KDPF Outlet Press Sens Low Error (PC200LC_10-CA3134-400-A-
Z0-A)
Action level Failure code KDPF Outlet Pressure Sensor Low Error
Failure
Detail of • Low voltage appears in signal circuit of KDPF outlet pressure sensor.
failure
• Takes it that KDPF outlet pressure is at estimated value (gauge pressure) and allows
Action of engine to run
displayed.)
Problem on
• None
machine
• If failure code [CA1696] is not displayed but failure code [CA1881] is on screen, sensor
connector is probably disconnected or 5 V circuit probably has open circuit (defective
Related contact of connector).
information • This failure code appears if sensor connector is disconnected.
• Signal voltage from KDPF outlet pressure sensor can be checked with monitoring
• Delta pressure sensed by KDPF outlet pressure sensor can be checked with monitoring
equipment" in "Checks before troubleshooting" of "General information on
Defective wiring troubleshooting", and check it.
harness connector
Voltage Between E25 (female) (4) and (1) 4.75 to 5.25
V
2. Disconnect connectors CE03 and E25, and connect T-adapter to each
female side.
Open circuit in wiring
harness a If no failure is found by check on cause 2, this
check is not required. Max. 10 z
3 (wire breakage or Between CE03 (female) (43) and E25 (female) (1)
defective contact of
a If no failure is found by check on cause 2, this
check is not required. Max. 10 z
Between CE03 (female) (52) and E25 (female) (4)
Between CE03 (female) (58) and E25 (female) (3) Max. 10 z
harness 2. Disconnect connectors CE03 and E25, and connect T-adapter to either
4 female side.
(contact with ground
Between ground and CE03 (female) (58) or E25 Min. 100 kz
circuit) Resistance (female) (3)
PC360LC-10 40-333
40 Troubleshooting

2. Disconnect connectors CE03 and E25, and connect T-adapter to female
side of CE03.
Short circuit in wiring a Check by using multimeter in continuity mode.
5
harness No
Continuity
is heard)
Defective KDPF outlet 2. Insert T-adapter into connector E25.
Voltage Between E25 (3) and (1) 0.5 to 4.5 V
Defective engine If this failure code appears and no failure is found by above checks, engine
7
controller controller is defective. (Since this is an internal defect, troubleshooting cannot
be performed.)
Circuit diagram related to KDPF outlet pressure sensor
40-334 PC360LC-10
40 Troubleshooting
Failure code [CA3135] KDPF Outlet Press Sens In Range Error (PC300-CA3135-
400-A-Z0-A)
Action level Failure code KDPF Outlet Pressure Sensor In Range Error
Failure
Detail of • Pressure value sensed by KDPF outlet pressure sensor is higher than normal value.
failure (Signal voltage from sensor is within "operating" range.)
• Takes it that KDPF outlet pressure is at estimated value (gauge pressure) and allows
Action of engine to run
displayed.)
Problem on
• None
machine
• Signal voltage from KDPF outlet pressure sensor can be checked with monitoring
• Outlet pressure sensed by KDPF outlet pressure sensor can be checked with monitoring
a Use "Short-circuit connector: 799T-601-4670" (its wiring is not identical with that of "Short-
circuit connector: 799-601-4611).
O
operation for
4680" is used.
2 information on troubleshooting", and check it and fix trouble as
connector
needed.
PC360LC-10 40-335
40 Troubleshooting

Defective wiring harness or If failure code [CA3134] is not displayed, wiring harness or engine
3 engine controller controller is defective.
2. Disconnect connector E25 and connect short-circuit connector to
female side.
a To connect 5 V line to signal line (to short pin (4) to pin (3) of
Defective wiring harness or connector E25).
3 engine controller 3. Turn starting switch to ON position.
Defective KDPF outlet a If failure codes [CA3134] and [CA3133] are displayed in check on
4 pressure sensor cause 3, KDPF outlet pressure sensor is defective.
each female side.
tance
(female) (4)

Ground fault in wiring 2. Disconnect connectors EC3 and E25, and connect T-adapter to
(contact with ground circuit) Resis- Between ground and CE03 (female) (58) or
E25 (female) (3) Min. 100 kz
tance

Continuity is heard)
40-336 PC360LC-10
40 Troubleshooting

1. Remove KDPF delta pressure sensor tube.
2. Clean KDPF delta pressure sensor tube to clear clogging.
3. Check KDPF delta pressure sensor tube for cracks and damage.
4. Install KDPF delta pressure sensor tube with both tube ends
connected securely.
Defective KDPF delta
8 • Reference
pressure sensor tube
How to check KDPF delta pressure sensor tube for clogging
2. Monitor outlet pressure sensed by KDPF outlet pressure sensor on
monitoring screen of machine monitor.
Code 47,000 (kPa) 0 ± 3 (kPa)

2. Disconnect connector E26 (in KDPF temperature sensor consolidating box) and install dummy
temperature sensor to wiring harness side.
4. Monitor KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet temperature, and check
that each temperature ranges from approximately 560 to 590°C. For details, see Related information.
6. Referring to Related information, display KDOC inlet and outlet temperatures and KDPF outlet
temperature.
7. After finishing warm-up operation, set swing lock switch to OFF position and working mode to P-mode.
8. Perform arm IN relief for continuous 40 seconds.
a If failure code disappears after implementing steps 1 to 7, repair work is complete.
10.Remove dummy temperature sensor and restore connector connection.
command.
PC360LC-10 40-337
40 Troubleshooting
40-338 PC360LC-10
40 Troubleshooting
Failure code [CA3251] KDOC Inlet Temp High Error (PC200LC_10-CA3251-400-A-Z0-A)
Action level Failure code KDOC Inlet Temperature High Error

Failure
Detail of • KDOC inlet temperature remains at high level.
failure
controller • You can cancel above measures by "turning starting switch to OFF position once, then
machine
injury.
Related • Temperature sensed by KDPF outlet temperature sensor can be checked with monitoring
• Misfire of cylinder can induce following phenomena.
1. Combustion is impaired causing high exhaust temperature.
2. Cylinders other than disabled cylinder may increase their fuel injection in order to
compensate for torque drop, causing high exhaust temperature.
of KDPF".
Machine O
clearing
Defective KDOC inlet If failure code [CA3313], [CA3314] or [CA3315] is also displayed,
1 temperature sensor perform troubleshooting for [CA3313], [CA3314] or [CA3315] first.
2
needed.
PC360LC-10 40-339
40 Troubleshooting

2. Disconnect connectors CE03 and TEMP1 (KDOC inlet temperature
sensor), and connect T-adapter to female side of CE03.
Continuity
2. Use monitoring function to display signal voltages and temperatures
from KDOC inlet temperature sensor, KDOC outlet temperature
sensor, and KDPF outlet temperature sensor on screen.
3. Run engine at idle for 10 minutes.
4. Note temperature values (after checking that they are stabilized).
5. Monitor temperature from each sensor.
Defective KDOC inlet
4 temperature sensor If temperature of any temperature sensor fluctuates 24°C or greater,
regard that temperature sensor as defective.
a If none of temperature sensor values changes more than 24°C,
problem is not in sensor system. Perform checks on causes 5 and
after.
a If another failure code appears with engine running at idle, perform
Check intake system hoses, clamps, and tubes for damage and
5 Malfunction of intake system
loosening. Repair as necessary. (Repair intake air leaks.)
Perform cylinder cutout mode operation to identify disabled cylinder (see
6 Defective injector
Testing and adjusting, "Handling of cylinder cutout mode operation).
2. Check for oil or fuel inside turbocharger exhaust connector.
Oil leak into turbocharger • If oil or fuel is found, visually check for oil leaks from EGR valve and
7
exhaust connector turbocharger. Repair if any failure is found.
a Wipe off oil and fuel from piping.
Check exhaust system between turbocharger and KDPF for oil or fuel
leaking in.
Oil leak into exhaust
8 connector and ducts leading • Wipe off oil or fuel if found.
to KDPF a If trace of oil or fuel leakage into KDPF is found, check KDPF, and
clean or replace it as necessary.
If failure code disappears, repair is complete.
command.
40-340 PC360LC-10
40 Troubleshooting
PC360LC-10 40-341
40 Troubleshooting
Failure code [CA3253] KDOC Temp Error - Non Regeneration (PC200LC_10-CA3253-

400-A-Z0-A)
Action level Failure code KDOC Temperature Error - Non Regeneration

Failure
Detail of • KDOC outlet temperature remains at high level when active regeneration is not
failure performed.
controller
machine
injury.
Related function. (Code: 47201 (V))
2. Since cylinders other than disabled cylinder increase their fuel injection to compensate
for torque drop, exhaust temperature may rise and KDOC inlet temperature high error
may be generated.
of KDPF".
O
operation for
4680" is used.
Defective KDOC inlet Perform checks on causes 1 and 3 to 5 of troubleshooting for failure
1 temperature sensor code [CA3251] (causes related to sensor and wiring harness).
Defective KDOC outlet Perform checks on causes 1 and 3 to 5 of troubleshooting for failure
2 temperature sensor code [CA3254] (causes related to sensor and wiring harness).
3 Defective KDOC 1. Remove KDPF.

2. Remove KDOC.
40-342 PC360LC-10
40 Troubleshooting

a When KDOC in KDPF is replaced, perform reset procedure for
KDOC change and then finish troubleshooting without performing
manual stationary regeneration.
(See check on cause 7 of failure code [CA2637])
soot or not.
(KDOC cleaning)
2. Start engine and run it at low idle for approximately 15 minutes.
• If failure code disappears, repair is complete.
If failure code is not cleared, perform following steps.
a If failure code remains uncleared after above steps 1 and 2 are implemented, following temperature
requirements are included in clearing condition. Steps 4 and 6 are required to satisfy temperature
requirements.
• KDOC inlet temperature X 200°C
• KDOC outlet temperature X 200°C
3. Use monitoring function to display KDOC inlet and outlet temperatures.
6. Run that track idle off ground for 3 minutes with fuel control dial at MAX position and travel speed at Hi
setting.
• After above steps are implemented, if failure code is not cleared because of low ambient temperature
(at -20°C level), perform following steps.
10.Monitor KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet temperature, and check
11.Start engine and run it at low idle (with no load) for approximately 15 minute.
If failure code disappears after implementing steps 7 to 11, repair work is complete.
12.Turn engine starting switch to OFF position.
13.Remove dummy temperature sensor to restore connector connection.
command.
PC360LC-10 40-343
40 Troubleshooting
40-344 PC360LC-10
40 Troubleshooting
Failure code [CA3254] KDOC Outlet Temp High Error 1 (PC200LC_10-CA3254-400-A-Z0-A)
Action level Failure code KDOC Outlet Temperature High Error 1

Failure
Detail of • KDOC outlet temperature remains at high level.
failure
controller
machine
injury.
of KDPF".
Machine O
clearing
Defective KDOC outlet If failure code [CA3316], [CA3317], or [CA3318] appears, perform
1 temperature sensor troubleshooting for [CA3316], [CA3317] or [CA3318] first.
connector
needed.
PC360LC-10 40-345
40 Troubleshooting

2. Disconnect connectors CE03 and TEMP2 (KDOC outlet temperature
Continuity
Defective KDOC outlet
after.
7
leaking in.
1. Remove KDPF.
2. Remove KDOC.
a When KDOC of KDPF is replaced, perform reset procedure for
KDOC change and then finish troubleshooting without performing
9 Defective KDOC manual stationary regeneration (see check on cause 7 of failure
code [CA2637]).
soot or not.
(KDOC cleaning)
40-346 PC360LC-10
40 Troubleshooting

4. End regeneration for service.
(Perform regeneration for service for 15 minutes and more from its start.)
If failure code disappears when regeneration for service is ended, repair is complete.
command.
PC360LC-10 40-347
40 Troubleshooting
Failure code [CA3255] KDPF Temp Error - Non Regeneration (PC200LC_10-CA3255-

400-A-Z0-A)
Action level Failure code KDPF Temperature Error - Non Regeneration

Failure
Detail of • KDPF outlet temperature remains at high level when active regeneration is not performed.
failure
controller
machine
injury.
of KDPF".
O
operation for
4680" is used.
Defective KDPF outlet If failure code [CA3319], [CA3321] or [CA3322] is also displayed,
2
needed.
2. Disconnect connectors CE03 and TEMP3 (KDPF outlet temperature
Continuity is heard)
40-348 PC360LC-10
40 Troubleshooting

Defective KDPF outlet 5. Monitor temperature from each sensor.
• If none of temperature sensor values changes more than 24°C,
after.
• If another failure code appears with engine running at idle, perform
2. Check inside of turbocharger exhaust connector for adhesion of oil
Oil leak into turbocharger and fuel.
7 • If oil or fuel is found, visually check for oil leaks from EGR valve and
exhaust connector
turbocharger. Repair if any failure is found.
leaking in.
Oil leak into exhaust • Wipe off oil or fuel if found.
8 connector and ducts leading
PC360LC-10 40-349
40 Troubleshooting

1. Turn starting switch from OFF position to ON position and leave it there for 1 minute.
a If failure code remains uncleared after above steps 1 and 2 are implemented, following temperature
requirements are included in clearing condition. Steps 3 and 4 are required to satisfy temperature
requirements.
• KDOC outlet temperature X 200 °C
• KDPF outlet temperature X 200 °C
3. Use monitoring function to display KDOC inlet and KDPF outlet temperatures.
6. Run that track idle off ground for continuous 3 minutes with fuel control dial at MAX position and travel
speed at Hi setting.
• After above steps are implemented, if failure code is not cleared because of low ambient temperature
(at -20°C level), perform following steps.
10.Monitor KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet temperature, and check
11.Start engine and run it at low idle (with no load) for approximately 15 minute.
If failure code disappears after implementing steps 7 to 11, repair work is complete.
12.Turn engine starting switch to OFF position
13.Remove dummy temperature sensor to restore connector connection.
command.
40-350 PC360LC-10
40 Troubleshooting
Failure code [CA3256] KDPF Outlet Temp High Error 1 (PC200LC_10-CA3256-400-A-Z0-A)
Action level Failure code KDPF Outlet Temperature High Error 1

Failure
Detail of • KDPF outlet temperature remains at high level.
failure
controller
machine
injury.
of KDPF".
Machine O
clearing
2
needed.
PC360LC-10 40-351
40 Troubleshooting

Between CE03 (female) (54) and each pin No continuity (no sound
other than pin (54) is heard)
Defective KDPF outlet 5. Monitor temperature from each sensor.
after.
exhaust connector
leaking in.
4. End regeneration for service.
(Perform regeneration for service for 15 minutes and more from its start.)
If failure code disappears when regeneration for service is ended, repair is complete.
command.
40-352 PC360LC-10
40 Troubleshooting
PC360LC-10 40-353
40 Troubleshooting
Failure code [CA3311] KDOC Outlet Temp High Error 2 (PC200LC_10-CA3311-400-A-Z0-A)
Action level Failure code KDOC Outlet Temperature High Error 2

Failure
Detail of • KDOC outlet temperature remains extremely high relative to KDOC inlet temperature.
failure
controller
machine
injury.
Related • Temperature sensed by KDOC outlet temperature sensor can be checked with monitoring
of KDPF".
OFF position. So when you restart engine, wait 1 minute minimum before turning starting
switch to the ON position again.
Machine O
operation for C. Machine operation for confirming completion of repair
clearing
failure code a This failure code disappears when starting switch is turned from OFF position to ON
position after repair. However, following machine operation must be done to confirm
completion of repair.
Defective KDOC outlet If failure code [CA3316], [CA3317], or [CA3318] appears, perform
1 temperature sensor troubleshooting for [CA3316], [CA3317] or [CA3318] first.
2
needed.
2. Disconnect connectors CE03 and TEMP2 (KDOC outlet temperature
Continuity
40-354 PC360LC-10
40 Troubleshooting

Defective KDOC outlet 5. Monitor temperature from each sensor.
after.
exhaust connector
leaking in.
C. Machine operation for confirming completion of repair
a Failure code disappears once when starting switch is turned from OFF position to ON position. Check
that cleared failure code is not generated again when engine runs at low idle.
a If this failure code appears when starting switch is turned to ON position but engine is not started, perform
troubleshooting for following failure codes, too, after finishing troubleshooting and repair for this code.
• [CA3316] KDOC Outlet Temp Sens Low Error
• [CA3317] KDOC Outlet Temp Sens High Error
PC360LC-10 40-355
40 Troubleshooting
40-356 PC360LC-10
40 Troubleshooting
Failure code [CA3312] KDPF Outlet Temp High Error 2 (PC200LC_10-CA3312-400-A-Z0-A)
Action level Failure code KDPF Outlet Temperature High Error 2

Failure
Detail of • KDPF outlet temperature remains at very high level.
failure
controller
machine
injury.
of KDPF".
Machine O
operation for C. Machine operation for confirming completion of repair
clearing
failure code a This failure code disappears when starting switch is turned from OFF position to ON
position after repair. However, following machine operation must be done to confirm
completion of repair.
Defective wiring harness equipment" in "Checks before troubleshooting" of "General information
2
connector on troubleshooting", and check it and fix trouble as needed.
PC360LC-10 40-357
40 Troubleshooting

Continuity
Defective KDPF outlet
after.
7
leaking in.
C. Machine operation for confirming completion of repair
a Failure code disappears once when starting switch is turned from OFF position to ON position. Check
that cleared failure code is not generated again when engine runs at low idle.
a If this failure code appears when starting switch is turned to ON position but engine is not started, perform
troubleshooting for following failure codes, too, after finishing troubleshooting and repair for this code.
• [CA3319] KDPF Outlet Temp Sens Low Error
• CA3321] KDPF Outlet Temp Sens High Error
40-358 PC360LC-10
40 Troubleshooting
PC360LC-10 40-359
40 Troubleshooting
Failure code [CA3313] KDOC Inlet Temp Sensor Low Error (PC200LC_10-CA3313-400-A-
Z0-A)
Action level Failure code KDOC Inlet Temperature Sensor Low Error
Failure
Detail of • Low voltage appears in KDOC inlet temperature sensor circuit.
failure
• Uses KDOC outlet temperature for KDOC inlet temperature to run engine.
(If failure is detected in KDOC outlet temperature sensor, too, controller takes it that
Action of KDOC inlet temperature is at default value (250°C) and allows engine to run.)
machine
injury.
Related
information
• If sensor connector is disconnected or open circuit occurs, this failure code does not
appear but failure code [CA3314] for "High Error" appears.
To avoid error due to improper operation, start and run engine at idle for 1 minute. If this
failure code is cleared, repair is complete.
troubleshooting", and check it.
Defective wiring 2. Turn starting switch to ON position.
1
harness connector
40-360 PC360LC-10
40 Troubleshooting

2. Disconnect TEMP1 (KDOC inlet temperature sensor).
If this failure code changes to [CA3314], KDOC inlet temperature sensor is
defective.
a If this failure code still remains displayed, wiring harness or engine
• Reference
Defective KDOC inlet 2. Disconnect connector TEMP1 and connect T-adapter to female side.
2 temperature sensor -10°C 33 to 65 kz
0°C 25 to 47 kz
7.8 to 12.2
Between TEMP1 (female) (1) and (2) 50°C
kz
a Temperature-Resistance 3.2 to 4.5
Resistance 100°C
characteristics kz
200 to 240
400°C
z
700°C 64 to 69 z
Between TEMP1 (female) (1) and ground Min. 100 kz
harness 2. Disconnect connectors CE03 and TEMP1, and connect T-adapter to
(contact with ground female side of CE03 or male side of TEMP1.
circuit)
3
(including wiring Between ground and CE03 (female) (45) or TEMP1
harness in KDPF Resistance (male) (1) Min. 100 kz
temperature sensor
consolidating box)
Short circuit in wiring 2. Disconnect connectors CE03 and TEMP 1, and connect T-adapter to
harness female side of CE03.
(including wiring a Check by using multimeter in continuity mode.
4
harness in KDPF No
temperature sensor Between CE03 (female) (45) and each pin other continuity
consolidating box) Continuity
is heard)
a If no failure is found by checks on causes 3 and 4, this check is not
required.
2. Disconnect connector E26 and connect T-adapter to male side.
3. Disconnect connectors TEMP1, TEMP2, and TEMP3.
Defective KDPF
5 temperature sensor a If no failure is found by check on cause 3, this
consolidating box check is not required. Min. 100 kz
Between E26 (male) (3) and ground
Resistance
check is not required. Min. 100 kz
Between E26 (male) (3) and each pin other than
pin (3)
harness
6 2. Disconnect connectors CE03 and E26, and connect T-adapter to either
(contact with ground female side.
circuit) Between ground and CE03 (female) (45) or E26 Min. 100 kz
Resistance (female) (3)
PC360LC-10 40-361
40 Troubleshooting

side of CE03.
harness
No
Continuity
is heard)
2. If this failure code appears, perform procedure for <How to clear failure
Defective engine code> in "Related information".
8
controller If this failure code is still displayed and no failure is found by above checks,
engine controller is defective. (Since this is an internal defect, troubleshooting
cannot be performed.)
40-362 PC360LC-10
40 Troubleshooting
Failure code [CA3314] KDOC Inlet Temp Sens High Error (PC200LC_10-CA3314-400-A-Z0-
A)
Action level Failure code KDOC Inlet Temperature Sensor High Error
Failure
Detail of • High voltage appears in KDOC inlet temperature sensor circuit.
failure
controller • Closes EGR valve
machine
injury.
Related
information
• If failure codes [CA3317] and [CA3319] are also displayed, connector in KDPF
temperature sensor consolidating box may be disconnected or probably has open circuit
(defective contact of connector) in ground line.
1
harness connector
PC360LC-10 40-363
40 Troubleshooting

2. Disconnect connector TEMP1 (KDOC inlet temperature sensor) and
connect T-adapter to male side.
3. Connect T-box to T-adapter and connect pins (1) and (2) of T-box with
jumper cable.
a To connect ground line to signal line
If this failure code changes to [CA3313] , KDOC inlet temperature sensor is
defective.
a If this failure code remains displayed, wiring harness or engine controller is
Defective KDOC inlet defective.
2 temperature sensor • Reference
2. Disconnect connector TEMP1 and connect T-adapter to female side.
-10°C 33 to 65 kz
0°C 25 to 47 kz
7.8 to 12.2
kz
Resistance a Temperature-Resistance 3.2 to 4.5
100°C
characteristics kz
200 to 240
400°C
z
700°C 64 to 69 z
Open or short circuit in 1. Turn starting switch to OFF position.
wiring harness 2. Disconnect connector CE03, and connect T-adapter to female side.
(including wiring Between CE03 (female) (45) and (19)
3
harness in KDPF 64 z to 65
temperature sensor Resistance a Use above Temperature-Resistance
kz
consolidating box) characteristics as resistance criteria.
harness
(wire breakage or
2. Disconnect connectors CE03 and TEMP1, and connect T-adapters to
female side of CE03 and male side of TEMP1.
4 connector)
Between CE03 (female) (45) and TEMP1 (male) (1) Max. 10 z
(including wiring
Between CE03 (female) (19) and TEMP1 (male) (2)
harness in KDPF Resistance
temperature sensor Max. 10 z
consolidating box)
2. Disconnect connectors CE03 and TEMP 1, and connect T-adapter to
harness
5 No
harness in KDPF
temperature sensor continuity
Between CE03 (female) (45) and each pin other
consolidating box) Continuity (No sound
than pin (45)
is heard)
40-364 PC360LC-10
40 Troubleshooting

a If no failure is found by checks on causes 3 to 5, this check is not required.
3. Disconnect connectors TEMP1, TEMP2, and TEMP3, and connect T-
adapter to male side of TEMP1.
a If no failure is found by check on cause 3 or 4,
Defective KDPF this check is not required. Max. 10 z
6 temperature sensor Between E26 (male) (2) and TEMP1 (male) (2)
consolidating box
Resistance
Between E26 (male) (3) and TEMP1 (male) (1)
pin (3)
Open circuit in wiring a If no failure is found by check on cause 3 or 4, this check is not required.
harness 1. Turn starting switch to OFF position.
7 (wire breakage or 2. Disconnect connectors CE03 and E26, and connect T-adapter to each
defective contact of female side.
connector) Between CE03 (female) (45) and E26 (female) (3) Max. 10 z
Resistance
side of CE03.
harness
No
Continuity
is heard)
9
PC360LC-10 40-365
40 Troubleshooting
40-366 PC360LC-10
40 Troubleshooting
Failure code [CA3315] KDOC Inlet Temp Sens In Range Error (PC200LC_10-CA3315-
400-A-Z0-A)
Action level Failure code KDOC Inlet Temperature Sensor In Range Error
Failure
• Difference between temperature sensed by KDOC inlet temperature sensor and that by
Detail of KDOC outlet temperature sensor differs from expected value.
failure (Signal voltage is within input range.)
machine
injury.
Related • Signal voltage from KDPF outlet temperature sensor can be checked with monitoring
information function. (Code: 47201 (V))
of KDPF".
O
operation for
4680" is used.
Defective KDOC inlet If failure code [CA3313] or [CA3314] is displayed, perform
1 temperature sensor troubleshooting for it first.
PC360LC-10 40-367
40 Troubleshooting

2
needed.
2. Disconnect TEMP1 (KDOC inlet temperature sensor).

3 engine controller 2. Disconnect connector TEMP1 and connect T-adapter to male side.
3. Connect T-box to T-adapter and connect pins (1) and (2) of T-box
with jumper cable.
2. Disconnect connectors CE03 and TEMP1, and connect T-adapters
to female side of CE03 and male side of TEMP1.
4 Between CE03 (female) (45) and TEMP1
(including wiring harness in Max. 10 z
Resis- (male) (1)
KDPF temperature sensor
tance Between CE03 (female) (19) and TEMP1
consolidating box) Max. 10 z
(male) (2)
(contact with ground circuit) female side of CE03 or male side of TEMP1.
5
(including wiring harness in
KDPF temperature sensor TEMP1 (male) (1) Min. 100 Kz
tance
consolidating box)
Short circuit in wiring harness 2. Disconnect connectors CE03 and TEMP1, and connect T-adapter to
(including wiring harness in female side of CE03.
6
KDPF temperature sensor a Check by using multimeter in continuity mode.
consolidating box) Between CE03 (female) (45) and No continuity (no sound
Continuity
40-368 PC360LC-10
40 Troubleshooting

3. Disconnect connectors TEMP1, TEMP2, and TEMP3, and connect
T-adapter to male side of TEMP1.
Between E26 (male) (2) and TEMP1 (male)
(2)
Defective KDPF temperature a If no failure is found by check on cause 4,

7 sensor consolidating box this check is not required. Max. 10 z
Resis- (1)
tance
this check is not required. Min. 100 Kz
Between E26 (male) (3) and each pin other
than pin (3)
Open circuit in wiring 2. Disconnect connectors CE03 and E26, and connect T-adapter to
harness each female side.
8
(wire breakage or defective Between CE03 (female) (45) and E26
contact of connector) Max. 10 z
Resis- (female) (3)
tance Between CE03 (female) (19) and E26

9 harness 2. Disconnect connectors CE03 and E26, and connect T-adapter to
Min. 100 Kz
tance E26 (female) (3)
10 Short circuit in wiring harness female side of CE03.
Continu- Between CE03 (female) (45) and No continuity (no sound is
ity each pin other than pin (45) heard)
2. Disconnect connector CE03, and connect T-adapter to female side.
harness
Between CE03 (female) (45) and (19)
11 (including wiring harness in
KDPF temperature sensor Resis- a Use Temperature-Resistance 64 z to 65 kz
consolidating box) tance characteristics shown below as resistance
criteria.
PC360LC-10 40-369
40 Troubleshooting

a When failure codes [CA3314] and [CA3313] are displayed in check
on cause 3 and no failure is found by checks on causes 2 and 4 to 10,
and if failure is found by check on cause 11, KDOC inlet temperature
• Reference
Defective KDOC inlet -10°C 33 to 65 kz
12 temperature sensor
0°C 25 to 47 kz
Between TEMP1 (female) (1) and 7.8 to 12.2
50°C
Resis- (2) kz
tance 3.2 to 4.5
a Temperature-Resistance 100°C
kz
characteristics 200 to 240
400°C
z
700°C 64 to 69 z
setting.
command.
40-370 PC360LC-10
40 Troubleshooting
Failure code [CA3316] KDOC Outlet Temp Sens Low Error (PC200LC_10-CA3316-400-A-
Z0-A)
Action level Failure code KDOC Outlet Temperature Sensor Low Error
Failure
Detail of • Low voltage appears in KDOC outlet temperature sensor circuit.
failure
• Uses KDOC inlet temperature for KDOC outlet temperature to run engine.
(If failure is detected in KDOC inlet temperature sensor, too, controller takes it that KDOC
Action of outlet temperature is at default value (250°C) and allows engine to run.)
machine
injury.
Related
information
1
harness connector
PC360LC-10 40-371
40 Troubleshooting

2. Disconnect TEMP2 (KDOC outlet temperature sensor).
If this failure code changes to [CA3317] , KDOC outlet temperature sensor is
defective.
defective.
• Reference
Defective KDOC outlet 2. Disconnect connector TEMP2 and connect T-adapter to female side.
0°C 25 to 47 kz
7.8 to 12.2
kz
Resistance 100°C
characteristics kz
200 to 240
400°C
z
700°C 64 to 69 z
(contact with ground female side of CE03 or male side of TEMP2.
circuit)
3
temperature sensor
consolidating box)
Short circuit in wiring 2. Disconnect connectors CE03 and TEMP2, and connect T-adapter to
4
harness in KDPF No
is heard)
required.
Defective KDPF
Resistance
pin (1)
harness
circuit) Between ground and CE03 (female) (48) or E26
Resistance (female) (1) Min. 100 kz
40-372 PC360LC-10
40 Troubleshooting

side of CE03.
harness
No
Continuity
is heard)
If this failure code appears, perform procedure for <How to clear failure
8
PC360LC-10 40-373
40 Troubleshooting
Failure code [CA3317] KDOC Outlet Temp Sens High Error (PC200LC_10-CA3317-400-
A-Z0-A)
Action level Failure code KDOC Outlet Temperature Sensor High Error
Failure
Detail of • High voltage appears in KDOC outlet temperature sensor circuit.
failure
machine
injury.
1
connector
40-374 PC360LC-10
40 Troubleshooting

2. Disconnect KDOC outlet temperature sensor (connector TEMP2)
and connect T-adapter to female side.
with jumper cable.
If this failure code changes to [CA3316], KDOC outlet temperature
Defective KDOC outlet a If this failure code remains displayed, wiring harness or engine
2 temperature sensor controller is defective.
• Reference
2. Disconnect connector TEMP2 and connect T-adapter to female
side.
-10°C 33 to 65 kz
Between TEMP2 (female) (1) 0°C 25 to 47 kz
Resis- and (2) 50°C 7.8 to 12.2 kz
tance a Temperature-Resistance 100°C 3.2 to 4.5 kz
characteristics 400°C 200 to 240 z
700°C 64 to 69 z
Open or short circuit in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connector CE03, and connect T-adapter to female side.
3 (including wiring harness in Between CE03 (female) (48) and (19)
KDPF temperature sensor Resis-
a Use above Temperature-Resistance 64 z to 65 kz
consolidating box) tance
characteristics as resistance criteria.
(wire breakage or defective 2. Disconnect connectors CE03 and TEMP2, and connect T-adapters
contact of connector) to female side of CE03 and male side of TEMP2.
4
(including wiring harness in Between CE03 (female) (48) and TEMP2
KDPF temperature sensor Max. 10 z
Resis- (male) (1)
consolidating box) tance Between CE03 (female) (19) and TEMP2
(male) (2) Max. 10 z

2. Disconnect connectors CE03 and TEMP2, and connect T-adapter
Short circuit in wiring harness to female side of CE03.
5 (including wiring harness in a Check by using multimeter in continuity mode.

KDPF temperature sensor No continuity
consolidating box) Between CE03 (female) (48) and each pin (No sound is
Continuity
other than pin (48) heard)
PC360LC-10 40-375
40 Troubleshooting

a If no failure is found by checks on causes 3 to 5, this check is not
required.
a If no failure is found by check on cause
3 or 4, this check is not required. Max. 10 z
Defective KDPF temperature Between E26 (male) (2) and TEMP2
6 sensor consolidating box (male) (2)
Resis- 3 or 4, this check is not required. Max. 10 z
tance Between E26 (male) (1) and TEMP2
(male) (1)
5, this check is not required. Min. 100 kz
Between E26 (male) (1) and each pin
other than pin (1)
a If no failure is found by check on cause 3 or 4, this check is not
required.
Open circuit in wiring harness 2. Disconnect connectors CE03 and E26, and connect T-adapter to
contact of connector) Between CE03 (female) (48) and E26
Max. 10 z
Resis- (female) (1)

No continuity
Between CE03 (female) (48) and each pin
other than pin (48)
heard)
2. If this failure code appears, perform procedure for <How to clear
Defective engine controller failure code> in "Related information".
9
If this failure code is still displayed and no failure is found by above
checks, engine controller is defective. (Since this is an internal defect,
40-376 PC360LC-10
40 Troubleshooting
PC360LC-10 40-377
40 Troubleshooting
Failure code [CA3318] KDOC Outlet Temp Sens In Range Error (PC200LC_10-
CA3318-400-A-Z0-A)
Action level Failure code KDOC Outlet Temperature Sensor In Range Error.
Failure
• Difference between temperature sensed by KDOC outlet temperature sensor and that by
Detail of KDOC inlet temperature sensor differs from expected value.
machine
injury.
of KDPF".
O
operation for
4680" is used.
Defective KDOC outlet If failure code [CA3316] or [CA3317] is displayed, perform
connector
needed.
40-378 PC360LC-10
40 Troubleshooting

2. Disconnect TEMP2 (KDOC outlet temperature sensor).

3 engine controller 2. Disconnect connector TEMP2 and connect T-adapter to male side.
with jumper cable.
2. Disconnect connectors CE03 and TEMP2, and connect T-adapter to
Resis- (male) (1)
(male) (2)
5
Resis- Between ground and CE03 (female) (48) or Min. 100
KDPF temperature sensor TEMP2 (male) (1)
tance Kz
consolidating box)
6
Continuity

7 this check is not required. Max. 10 z
sensor consolidating box
Resis-
tance a If no failure is found by check on cause 5, Min. 100
this check is not required. Kz
this check is not required. Min. 100
Between E26 (male) (1) and each pin other Kz
than pin (1)
PC360LC-10 40-379
40 Troubleshooting

contact of connector) Between CE03 (female) (48) and E26 (female)
Max. 10 z
Resis- (1)
tance Between CE03 (female) (19) and E26 (female)
(2) Max. 10 z

Resis- Between ground and CE03 (female) (48) or Min. 100
tance E26 (female) (1) Kz
Continuity
harness
KDPF temperature sensor Resis- a Use Temperature-Resistance 64 z to 65
consolidating box) tance characteristics shown below as resistance kz
criteria.
and if failure is found by check on cause 11, KDOC outlet
temperature sensor is defective.
• Reference
Defective KDOC outlet -10°C 33 to 65 kz
0°C 25 to 47 kz
Between TEMP2 (female) (1) and 7.8 to 12.2
50°C
Resis- (2) kz
tance 3.2 to 4.5
a Temperature-Resistance 100°C
kz
characteristics 200 to 240
400°C
z
700°C 64 to 69 z
40-380 PC360LC-10
40 Troubleshooting

setting.
command.
PC360LC-10 40-381
40 Troubleshooting
Failure code [CA3319] KDPF Outlet Temp Sens High Error (PC200LC_10-CA3319-400-A-
Z0-A)
Action level Failure code KDPF Outlet Temperature Sensor High Error
Failure
Detail of • High voltage appears in KDPF outlet temperature sensor circuit.
failure
• Uses KDOC outlet temperature for KDPF outlet temperature to run engine.
(If failure is detected in KDOC outlet temperature sensor, controller takes it that KDPF
machine
injury.
1
harness connector
40-382 PC360LC-10
40 Troubleshooting

2. Disconnect KDPF outlet temperature sensor (connector TEMP3) and
connect T-adapter to female side.
3. Connect T-box to T-adapter and connect pins (1) and (2) of T-box with
jumper cable.
If this failure code changes to [CA3321], KDPF outlet temperature sensor is
defective.
Defective KDPF outlet defective.
2 temperature sensor • Reference
-10°C 33 to 65 kz
0°C 25 to 47 kz
7.8 to 12.2
kz
Resistance a Temperature-Resistance 3.2 to 4.5
100°C
characteristics kz
200 to 240
400°C
z
700°C 64 to 69 z
Open or short circuit in 1. Turn starting switch to OFF position.
wiring harness 2. Disconnect connector CE03, and connect T-adapter to female side.
(including wiring Between CE03 (female) (54) and (19)
3
harness in KDPF 64 z to 65
temperature sensor Resistance a Use above Temperature-Resistance
kz
consolidating box) characteristics as resistance criteria.
harness
(wire breakage or
2. Disconnect connectors CE03 and TEMP3, and connect T-adapters to
4 connector)
Between CE03 (female) (54) and TEMP3 (male) (1) Max. 10 z
(including wiring
harness in KDPF Resistance
temperature sensor Between CE03 (female) (19) and TEMP3 (male) (2) Max. 10 z
consolidating box)
2. Disconnect connectors CE03 and TEMP3, and connect T-adapter to
harness
5 No
harness in KDPF
temperature sensor continuity
Between CE03 (female) (54) and each pin other
consolidating box) Continuity (No sound
than pin (54)
is heard)
PC360LC-10 40-383
40 Troubleshooting

a If no failure is found by checks on causes 3 to 5, this check is not required.
3. Disconnect connectors TEMP1, TEMP2, and TEMP3, and connect T-
adapter to male side of TEMP3.
Defective KDPF this check is not required. Max. 10 z
6 temperature sensor Between E26 (male) (2) and TEMP3 (male) (2)
consolidating box
Resistance
pin (4)
Open circuit in wiring a If no failure is found by check on cause 3 or 4, this check is not required.
7 (wire breakage or 2. Disconnect connectors CE03 and E26, and connect T-adapter to each
defective contact of female side.
connector) Between CE03 (female) (54) and E26 (female) (4) Max. 10 z
Resistance
side of CE03.
harness
No
Continuity
is heard)
9
40-384 PC360LC-10
40 Troubleshooting
PC360LC-10 40-385
40 Troubleshooting
Failure code [CA3321] KDPF Outlet Temp Sens Low Error (PC200LC_10-CA3321-400-A-
Z0-A)
Action level Failure code KDPF Outlet Temperature Sensor Low Error
Failure
Detail of • Low voltage appears in KDPF outlet temperature sensor circuit.
failure
machine
injury.
1
harness connector
40-386 PC360LC-10
40 Troubleshooting

2. Disconnect TEMP3 (KDPF outlet temperature sensor).
If this failure code changes to [CA3319], KDPF outlet temperature sensor is
defective.
defective.
• Reference
Defective KDPF outlet 2. Disconnect connector TEMP3 and connect T-adapter to female side.
0°C 25 to 47 kz
7.8 to 12.2
kz
Resistance 100°C
characteristics kz
200 to 240
400°C
z
700°C 64 to 69 z
harness 2. Disconnect connectors CE03 and TEMP3, and connect T-adapters to
(contact with ground female side of CE03 and male side of TEMP3.
circuit)
3
temperature sensor
consolidating box)
Short circuit in wiring 2. Disconnect connectors CE03 and TEMP3, and connect T-adapter to
4
harness in KDPF No
is heard)
required.
Defective KDPF
Resistance
pin (4)
harness
circuit) Between ground and CE03 (female) (54) or E26 Min. 100 kz
Resistance (female) (4)
PC360LC-10 40-387
40 Troubleshooting

side of CE03.
harness
No
Continuity
is heard)
8
40-388 PC360LC-10
40 Troubleshooting
Failure code [CA3322] KDPF Outlet Temp Sens In Range Error (PC200LC_10-
CA3322-400-A-Z0-A)
Action level Failure code KDPF Outlet Temperature Sensor In Range Error
Failure
Detail of • Temperature sensed by KDPF outlet temperature sensor differs from expected value.
machine
injury.
of KDPF".
O
operation for
4680" is used.
Defective KDPF outlet If failure code [CA3313] or [CA3314] is displayed, perform
Defective wiring harness
2 equipment" in "Checks before troubleshooting" of "General
connector
PC360LC-10 40-389
40 Troubleshooting

2. Disconnect TEMP3 (KDPF outlet temperature sensor).

3 engine controller 2. Disconnect TEMP3 and connect T-adapter to female side.
with jumper cable.
2. Disconnect connectors CE03 and TEMP3, and connect T-adapters
to female side of CE03 and male side of TEMP3.
Resis- (male) (1)
(male) (2)
5
KDPF temperature sensor TEMP3 (male) (1) Min. 100 Kz
tance
consolidating box)
6
Continuity
(2)

7 sensor consolidating box this check is not required. Max. 10 z
Resis- (1)
tance
Between E26 (male) (4) and each pin other
than pin (4)
40-390 PC360LC-10
40 Troubleshooting

contact of connector) Between CE03 (female) (54) and E26
Max. 10 z
Resis- (female) (4)

E26 (female) (4) Min. 100 Kz
tance
Continuity
harness
KDPF temperature sensor Resis- a Use Temperature-Resistance
64 z to 65 kz
consolidating box) tance characteristics shown below as
resistance criteria.
if failure is found by check on cause 11, KDOC inlet temperature
• Reference
Defective KDPF outlet 2. Disconnect connector TEMP3 and connect T-adapter to female side.
-10°C 33 to 65 kz
Between TEMP3 (female) (1) and 0°C 25 to 47 kz
Resis- (2) 50°C 7.8 to 12.2 kz
tance a Temperature-Resistance 100°C 3.2 to 4.5 kz
characteristics 400°C 200 to 240 z
700°C 64 to 69 z
PC360LC-10 40-391
40 Troubleshooting

setting.
command.
40-392 PC360LC-10
40 Troubleshooting
Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error (PC200LC_10-
CA3419-400-A-Z0-A)
Action level Failure code Mass Air Flow Sensor Supply Voltage High Error
Failure
Detail of • High voltage appears in power supply (12 V) circuit of mass air flow sensor.
failure
a If signal voltage of mass air flow sensor becomes abnormal, controller takes following
measures that are similar to those for failure codes [CA356] and [CA357].
Action of • Takes it that mass air flow is at fixed value (10 kg/min) and allows engine to run.
machine
information
Defective mass air flow 3. Turn starting switch to ON position.
2 sensor If this failure code does not appear, MAF sensor is defective.
(internal defect)
codes other than this code.
3 Defective wiring harness If this failure code does not appear, wiring harness is defective.
4 Defective engine controller Approx. 12
V
PC360LC-10 40-393
40 Troubleshooting
40-394 PC360LC-10
40 Troubleshooting
Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error (PC200LC_10-
CA3421-400-A-Z0-A)
Action level Failure code Mass Air Flow Sensor Supply Voltage Low Error
Failure
Detail of • Low voltage appears in power supply (12V) circuit of mass air flow sensor.
failure
a If signal voltage of mass air flow sensor becomes abnormal, controller takes following
measures that are similar to those for failure codes [CA356] and [CA357].
Action of • Takes it that mass air flow is at fixed value (10 kg/min) and allows engine to run.
machine
information
Defective mass air flow 3. Turn starting switch to ON position.
2 sensor If this failure code does not appear, MAF sensor is defective.
(internal defect)
Defective wiring harness or
3 If this failure code does not appear, wiring harness is defective.
connector
Ground fault in wiring harness 2. Disconnect connectors ECM J1 and P55, and connect T-adapters to
P55 (female) (2) Min. 1 Mz
tance
Resis- Between ECM J1 (female) (21) and (22) or
tance
6 Defective engine controller Approx. 12
V
PC360LC-10 40-395
40 Troubleshooting
40-396 PC360LC-10
40 Troubleshooting
Failure code [CA3741] Rail Press Valve Trip Error (D65-CA3741-400-A-Z0-A)
Action
Failure code Rail pressure valve Trip Error.
level Failure
L03 CA3741
Failure • Engine controller determines that common rail pressure limiter valve opens.
Action of • Lowers set value of common rail pressure.
controller
Problem on • Engine output lowers. Engine may not start again.
machine
function.
(Code: 36401 (V))
Related • Pressure sensed by common rail pressure sensor can be checked with monitoring
(Code: 36400 (MPa))
Common rail pressure limiter
valve is open.
PC360LC-10 40-397
40 Troubleshooting
Failure code [D110KB] Battery Relay Drive S/C (PC300-D110KB-400-A-Z0-A)
Action level Failure code Battery Relay Drive Short Circuit

Failure
L01 D110KB (Pump controller system)
Detail of • Abnormal current flows when outputting 24 V to battery relay primary circuit (coil side).
failure
• Stops 24 V output to battery relay primary circuit (coil side).
Action of • Even if cause of failure disappears, machine does not become normal until starting switch
controller is turned to OFF position.
Problem on • Each controller may fail in writing of data into its ROM (non-volatile memory).
machine
• As T-adapter for pump controller connector is "socket-type box", operating voltage cannot
be measured at pump controller connector.
Related • Output state (ON/OFF) to battery relay can be checked with monitoring function.
information (Code: 03700 Controller output 1)
• Method of reproducing failure code: Turn starting switch to ON position, then turn it to
OFF position.
Defective battery relay 1. Turn starting switch to OFF position.
1
(Internal short circuit) Continuity Between terminals R01 and R02 Continuity
2. Turn battery disconnect switch to OFF position (to prevent short
circuit during work).
Ground fault in wiring 3. Disconnect wires from terminals R01 and R02, and disconnect
2 harness (contact with ground connectors D01, H15 and CP02.
circuit) Between terminal R02 (BR) and ground Min. 1 Mz
Resis- Between ground and terminal CP02 (female)
tance (108), R02 (harness side), D01 (female) (1) or Min. 1 Mz
(2)
If no failure is found by above checks, pump controller is defective.
• Reference
2. Insert T-adapters into connector D01.
3 Defective pump controller
4. Measure voltage within 0.5 second after turning staring switch to
OFF position from ON position.
Voltage Between D01 (1) and ground 20 to 30 V
40-398 PC360LC-10
40 Troubleshooting
Circuit diagram related to battery relay
PC360LC-10 40-399
40 Troubleshooting
Failure code [D19JKZ] Personal Code Relay Abnormality (PC300-D19JKZ-400-A-Z0-A)
Action level Failure code Personal Code Relay Abnormality

Failure
L03 D19JKZ (Machine monitor system)
Detail of • Disconnection or short circuit was detected in primary coil side of personal code relay
failure circuit.
• None in particular (when open circuit is detected).
• Shuts of power supply to personal code relay (when short circuit is detected).
Action of • If cause of failure disappears, machine becomes normal by itself (when open circuit is
machine detected).
monitor • Even if cause of failure disappears, machine does not become normal until starting switch
is turned to OFF position (when short circuit is detected).
Problem on
machine
• This failure code is displayed only when engine lock function is enabled.
• Method of reproducing failure code: Turn starting switch ON (Disconnection). Trouble
Related cannot be reproduced on machine (Short circuit).
information • Troubleshooting for this failure code covers circuit starting from No. 3 fuse of fuse box
F01, through primary (coil) circuit of personal code relay R07, to machine monitor.
Defective No. 3 of fuse F01
1 When fuse is blown, ground fault may have probably occurred in circuit.
(3rd from right top)
Resis- Between R07 (male) (1) and (2)
200 to 600 z
tance
Defective personal code relay
2 1. Turn starting switch to OFF position.
R07
2. Replace relay R07 with preheat relay R18.
If this failure code disappears, original personal code relay R07 is
defective.
2. Remove fuse No. 3 of fuse box F01 (3rd fuse from right top).
3. Disconnect connectors CM01 and S14, and connect T-adapter to
Open circuit or short circuit or
3 female side of CM01.
ground fault in wiring harness
Between F01-3 and CM01 (female) (6) 200 to 600 z
Resis-
Between F01-3 or CM01 (female) (6) and
tance Min. 1 Mz
ground
4 Open circuit in wiring harness 3. Disconnect connector CM01 and relay R07, and connect T-adapters
to each female side.
Between F01-3 and R07 (female) (1) Max. 1 z
Resis-
Between R07 (female) (2) and CM01
tance Max. 1 z
(female) (6)
3. Disconnect connector CM01 and relay R07, and connect T-adapters
5 Ground fault in wiring harness to either female side.
Between F01-3 or R07 (female) (1) and
Min. 1 Mz
Resis- ground
tance Between R07 (female) (2) and ground, or
between CM01 (female) (6) and ground Min. 1 Mz
40-400 PC360LC-10
40 Troubleshooting

3. Disconnect connectors CM01 and relay R07, and connect T-adapter
to female side of connector CM01.
No continuity
Between CM01 (female) (6) and each pin
other than pin (6)
heard)
7 Defective machine monitor (Since this is an internal defect, troubleshooting cannot be performed.)
PC360LC-10 40-401
40 Troubleshooting
Circuit diagram related to personal code relay
40-402 PC360LC-10
40 Troubleshooting
Failure code [D811MC] KOMTRAX Error (PC400-D811MC-400-A-Z0-A)
Action level Failure code KOMTRAX Error

Failure
– D811MC (KOMTRAX system)
Detail of
• KOMTRAX malfunctions.
failure
Action of
controller
Problem on • KOMTRAX system does not operate properly.
machine
information
KOMTRAX is defective.
1 Malfunction of KOMTRAX
PC360LC-10 40-403
40 Troubleshooting
Failure code [D862KA] GPS Antenna Open Circuit (PC400-D862KA-400-A-Z0-A)
Action level Failure code GPS Antenna Open Circuit

Failure
– D862KA (KOMTRAX system)
Detail of • Open circuit is detected in GPS antenna circuit.
failure
monitor
Problem on • GPS positioning cannot work.
machine
information
Probable causes are defective GPS antenna, open circuit or short circuit
Defective GPS antenna or in antenna cable, and defective connection of antenna cable connector
1
antenna cable (GPS).
Structural illustration
40-404 PC360LC-10
40 Troubleshooting
Failure code [D8ALKA] System Operating Lamp Disconnection

(KOMTRAX) (PC300-D8ALKA-400-A-Z0-A)
Action level Failure code Operating Lamp Open Circuit (KOMTRAX)
Failure
— D8ALKA (KOMTRAX system)
• KOMTRAX determines that system operating lamp circuit is open because voltage of
Detail of output circuit remains at approximately 5 V or less for approximately 3 seconds after
failure starting switch is turned to ON position, during which KOMTRAX outputs no current to
system operating lamp.
controller
• While system operating lamp is lit, battery disconnect switch must not be turned to OFF
Problem on position. Turning battery disconnect switch to OFF position may destroy data stored in
machine KOMTRAX memory.
• Although KOMTRAX is not able to light up system operating lamp, no trouble will result
Related unless battery disconnect switch is turned to OFF position.
information • When controller lights up system operating lamp, output circuit voltage is at low level.
• Since no controller drives system operating lamp for approximately 3 seconds after
starting switch is turned to ON position, open circuit can be detected.
Defective fuse No. 16 in a If room lamp lights up, this check is not required.
1
fuse box F01. If fuse is blown, circuit probably has ground fault.

harness 2. Remove fuse No. 16 in fuse box F01.
3. Disconnect connectors CK01 and L19, and connect T-adapters to each
2 (Wire breakage or female side.
defective contact of Between CK01 (female) (15) and L19 (female) (2) Max. 1 z
Between F01-16 and L19 (female) (1) Max. 1 z
Defective KOMTRAX If no failure is found by above checks, KOMTRAX terminal is defective. (Since
terminal
PC360LC-10 40-405
40 Troubleshooting
Circuit diagram related to system operating lamp
40-406 PC360LC-10
40 Troubleshooting
Failure code [D8ALKB] System Operating Lamp Short Circuit

(KOMTRAX) (PC300-D8ALKB-400-A-Z0-A)
Action level Failure code Operating Lamp Short Circuit (KOMTRAX)
Failure
- D8ALKB (KOMTRAX system)
• KOMTRAX determines that system operating lamp circuit shorts because voltage of output
Detail of circuit does not become low level while KOMTRAX outputs current to system operating
failure lamp.
controller
Problem on position. Turning battery disconnect switch to OFF position may destroy data stored in
machine KOMTRAX memory.
Related • Although KOMTRAX is not able to light up system operating lamp, no trouble will result
information unless battery disconnect switch is turned to OFF position.
• When controller lights up system operating lamp, output circuit voltage is at low level.
2. Remove fuse No. 16 in fuse box F01.
Short circuit in wiring 3. Disconnect connectors CM01, CP02, CK01, CE03, and L19, and connect
1
harness T-adapter to female side of connector L19.
Resistance Between L19 (female) (1) and (2) Min. 1 Mz
Defective KOMTRAX If no failure is found by above checks, KOMTRAX terminal is defective. (Since
terminal
PC360LC-10 40-407
40 Troubleshooting
Failure code [D8AQKR] CAN2 Discon (KOMTRAX) (PC400-D8AQKR-400-A-Z0-A)
Action level Failure code CAN2 Disconnection (KOMTRAX)

Failure
– D8AQKR (Detected by machine monitor) (Machine monitor system)
Detail of • Machine monitor cannot recognize pump controller through CAN communication 2 line
failure (KOMNET/c).
Action of
machine • None
monitor
Problem on
• None
machine
• Start of CAN communication is recognized by each controller when ACC signal of starting
switch is received.
• If any of failure codes [DY20KA], [DY20MA] or [DW43KA] is displayed, pump controller
may be defective.
• Machine monitor indicates a CAN communication error in CAN2 with failure code
[DA2QKR], [DB2QKR], [D8AQKR], or [DAZQKR]. If all four of these failure code are
displayed, harness (CAN communication line) may have ground fault, short circuit, or hot
short circuit. Since air conditioner is also controlled via CAN communication, check
whether air conditioner can be operated (ON/OFF and air flow adjustment) on air
Related conditioner screen.
information a If ID controller is not installed, failure code [F7FQKR] is not generated. Therefore, the
number of failure codes that may be generated are four; [DA2QKR], [DB2QKR],
[D8AQKR], and [DAZQKR].
a Air conditioner can be operated even when a failure code is displayed on machine
monitor screen. If air conditioner is operated, there is no possibility of ground fault, short
circuit, or hot short circuit in harness (CAN communication line).
• Since each controller and machine monitor are directly connected to continuous power
supply, they receive continuous power even while starting switch is at OFF position.
• Since active CAN communication line signal is pulse voltage, it cannot be measured by
using multimeter.
2. Disconnect fusible link F05 and connect T-adapters to female side.
1 Defective fusible link F05 Resis- Between F05 (female) (1) and (2)
Max. 1 z
tance
a If fusible link is blown, circuit may have ground fault.
Defective fuse No. 17 in fuse
2 2. Remove fuse No. 17 of fuse box F01.
box F01
When fuse is blown, circuit may have ground fault.
Power supply to KOMTRAX Perform troubleshooting for E mode, "E-57".
3
terminal defective
Defective CAN [Perform troubleshooting for failure code [DB2QKR], cause 4 to 9.
4
communication 2 line
If no failure is found by above checks, KOMTRAX terminal is defective.
5 Defective KOMTRAX terminal
40-408 PC360LC-10
40 Troubleshooting
Failure code [DA20MC] Pump Controller Malfunction (PC400-DA20MC-400-A-Z0-A)
Action level Failure code Pump controller malfunction

Failure
– DA20MC (Pump controller system)
Detail of • Pump controller malfunctions.
failure
Action of
controller
Problem on • Pump controller does not function normally
machine
information
Malfunction of pump Pump controller is defective.
1
controller (Since this is an internal defect, troubleshooting cannot be performed.)
PC360LC-10 40-409
40 Troubleshooting
Failure code [DA22KK] Pump Solenoid Power Low Error (PC300-DA22KK-400-A-Z0-A)
Action level Failure code Pump solenoid power supply voltage low error
Failure
L03 DA22KK (Pump controller system)
Detail of • Power supply supply voltage of controller for driving solenoids is below 20 V.
failure
• Stops detection of failures (open circuit and short circuit) in all solenoid systems while this
Action of failure code is active.
• No solenoid valve is energized properly, so machine does not work properly.
Problem on (Work equipment, swing, and travel systems do not work.)
machine • Hydraulic fan does not rotate in reverse direction.
• If failure code [D110KB] is displayed, perform troubleshooting for it first.
Related • As T-adapter for pump controller connector is "socket-type box", operating voltage cannot
information be measured at pump controller connector.
1 Defective fusible link F04 If fusible link is blown, circuit probably has ground fault (see Cause 5).
Defective fuse No. 2 in fuse If fuse is blown, circuit probably has ground fault (see Cause 7).
2
box F01
3 Improper battery voltage 2. After measuring voltage, measure it again when starting engine.
Voltage Between battery (+) and ground 20 to 30 V
2. Disconnect connector CP02 and connect T-adapters to female side.
4 Defective wiring harness 3. Turn battery disconnect switch to ON position, and turn starting
switch to ON position.
Between ground and each of CP02 (female)
Voltage 20 to 30 V
(116), (118) and (121)
a fusible link or fuse is blown, replace it in advance.
Resis- Between R03 and each of CP02 (female) (116),
(118) and (121) Max. 1 z
5 Open circuit in wiring harness tance
a If no abnormality is found by above checks, this check is not
required.
1. Disconnect connector F04 and connect T-adapters to male side
furthermore.
Between F04 (male) (2) and each of CP02
Resis- (female) (116), (118) and (121) Max. 1 z
tance
Between F04 (male) (1) and terminal R03 (M) Max. 1 z
2. Remove wire from terminal R03.
Ground fault in wiring harness 3. Disconnect connectors F04 and CP02, and connect T-adapters to
6 (contact with ground circuit) female side of CP02 and male side of F04.
Between ground and CP02 (female)(116), (118)
Min. 1 Mz
Resis- or (121), or F04 (male) (2)
tance Between ground and F04 (male) (1) or terminal Min. 1 Mz
R03 (M)
40-410 PC360LC-10
40 Troubleshooting

Circuit diagram related to solenoid power supply
PC360LC-10 40-411
40 Troubleshooting
Failure code [DA25KP] 5V Sensor1 Power Abnormality (PC300-DA25KP-400-A-Z0-A)
Action level Failure code 5 V sensor 1 power supply abnormality.

Failure
― DA25KP (Pump controller system)
Detail of • Voltage of 5V sensor power supply output 1 circuit is below 2.5 V or above 6.0 V.
failure
• Stops output of power from 5V sensor power supply output 1.
• Signals of pressure sensors are not input normally.
• Error codes for failures in pressure sensors are also displayed.
Problem on • Travel and work equipment speeds are slow.
machine • Automatic travel speed selector function does not work (pump pressure sensor system).
• Auto-decelerator function remains activated or fine control performance of work
equipment is poor.
information
2. Disconnect following sensors one by one, and turn starting switch to ON
position for each troubleshooting.
a If this failure code disappears, disconnected sensor is defective.
a Since connector is disconnected, other failure codes appear. Ignore all
displayed failure codes other than this.
3. After each troubleshooting, turn starting swith to OFF position.
Bucket CURL pressure sensor P01
Boom LOWER pressure sensor P02
Swing (L) pressure sensor P03
Arm IN pressure sensor P04
Defective pressure
sensor Bucket DUMP pressure sensor P05
1
(internal short circuit) Boom RAISE pressure sensor P06
Swing (R) pressure sensor P07
Arm OUT pressure sensor P08
Connector L.H. travel FORWARD pressure sensor P09
L.H. travel REVERSE pressure sensor P10
R.H. travel FORWARD pressure sensor P11
RH. travel REVERSE pressure sensor P12
F pump pressure sensor P25
R pump pressure sensor P26
F pump swash plate sensor P27
R pump swash plate sensor P28
Service pressure sensor (dummy) P49
40-412 PC360LC-10
40 Troubleshooting

a To measure voltage before controller stops output of power.
Hot short circuit in wiring
harness 2. Disconnect connectors P01 to P12, P25 to P28, and P49.
2 3. Connect T-adapters to female side of connector P01.
(contact with 24 V circuit) 4. Turn starting switch to ON position (with connector disconnected).
Voltage Between P01 (female) (3) and ground 4.5 to 5.5
V
Ground fault in wiring harness 2. Disconnect connectors CP01, P01 to P12, and P49.
3 (contact with ground circuit) 3. Connect T-adapter to female side of connector CP01.
Resis- Between CP01 (female) (6) and ground
Min. 1 Mz
tance
PC360LC-10 40-413
40 Troubleshooting
Circuit diagram related to 5 V sensor power supply 1 circuit
40-414 PC360LC-10
40 Troubleshooting
Failure code [DA29KQ] Model Selection Abnormality (PC300-DA29KQ-400-A-Z0-A)
Action level Failure code Model Selection Abnormality

Failure
L01 DA29KQ (Pump controller system)
Detail of • Model code signal for model which is not registered in controller is input.
failure
• Controls machine by regarding machine as default model (PC300 standard specification
Action of machine).
controller • Even if cause of failure disappears, machine does not become normal until starting switch
is turned to OFF position.
Problem on • No problem appears if machine is PC300 standard specification machine.
machine • Overheating may occur in Colorado specification.
• Pat number of pump controller assembly can be checked with monitoring function.
(Code: 20229 Pump controller assembly part number
• Signal status (ON/OFF) of model selection signal can be checked by using monitoring
function.
(Code: 02201 Switch input 2)
a For standard specification, the followings
Related are correct.
information Model selection signal 1: OFF
Model selection signal 2: ON
Model selection signal 4: OFF
Standard specification
Pump controller with wrong 1. Use monitoring function to display assembly part number and check
1 part number whether it is identical to that listed in Parts book.
2. Disconnect connector S30, and connect T-adapter to female side.
Defective model selection Between S30 (female) (1) and (8) Min. 1 Mz
2 connector Between S30 (female) (1) and (2) Min. 1 Mz
(Internal open or short circuit) Resis- Between S30 (female) (2) and (3)
Max. 1 z
tance
Between S30 (female) (3) and (4) Min. 1 Mz
Between S30 (female) (7) and (8) Max. 1 z
Open circuit in wiring harness 2. Disconnect connector CP01 and connect T-adapter to female side.
3 (Wire breakage or defective Between CP01 (female) (21) and ground Max. 1 z
contact of connector) Resis- Between CP01 (female) (40) and ground
Max. 1 z
tance
Between CP01 (female) (58) and ground Max. 1 z
4 Short circuit in wiring harness 2. Disconnect connectors CP01 and S30, and insert T-adapters to S30.
Resis- Between S30 (1) and (8), and (3) and (4)
Min. 1 Mz
tance
Ground fault in wiring harness 2. Disconnect connector CP01 and connect T-adapter to female side.
5
(Contact with ground circuit) Resis- Between CP01 (female) (77) and ground
Min. 1 Mz
tance
If cause is not found by above checks, pump controller is defective.
6 Pump controller is defective.
PC360LC-10 40-415
40 Troubleshooting
Circuit diagram related to model selection abnormality (standard specification)
40-416 PC360LC-10
40 Troubleshooting
Failure code [DA2LKA] System Operating Lamp Disconnection (Pump

Con) (PC300-DA2LKA-400-A-Z0-A)
Action level Failure code Operating Lamp Open Circuit (Pump Controller)
Failure
- DA2LKA (Pump controller system)
• Pump controller determines that system operating lamp circuit is open because voltage of
Detail of output circuit remains at approximately 5 V or below for approximately 3 seconds after
failure starting switch is turned to ON position, during which pump controller outputs no current to
system operating lamp.
controller
Problem on position. If the battery disconnect switch is turned OFF, the data stored in the pump
machine controller memory may be destroyed.
• Although work equipment controller is not able to light up system operating lamp, no
Related trouble will result unless battery disconnect switch is turned to OFF position.
1

3. Disconnect connectors CP02 and L19, and connect T-adapters to each
defective contact of Between CP02 (female) (100) and L19 (female) (2) Max. 1 z
Pump controller is If no failure is found by above checks, monitor controller is defective. (Since
3 this is an internal defect, troubleshooting cannot be performed).
defective.
PC360LC-10 40-417
40 Troubleshooting
40-418 PC360LC-10
40 Troubleshooting
Failure code [DA2LKB] System Operating Lamp Short Circuit (Pump

Con) (PC300-DA2LKB-400-A-Z0-A)
Action level Failure code Operating Lamp Short Circuit (Pump Controller)
Failure
- DA2LKB (Pump controller system)
• Pump controller determines that system operating lamp circuit shorts because voltage of
Detail of output circuit does not become Low level while pump controller outputs current to system
failure operating lamp.
controller
Problem on position. If the battery disconnect switch is turned OFF, the data stored in the pump
machine controller memory may be destroyed.
Related • Although work equipment controller is not able to light up system operating lamp, no
information trouble will result unless battery disconnect switch is turned to OFF position.
1
Pump controller is If no failure is found by above checks, monitor controller is defective. (Since
2 this is an internal defect, troubleshooting cannot be performed).
defective.
PC360LC-10 40-419
40 Troubleshooting
Failure code [DA2QKR] CAN2 Discon ( Pump Con) (PC300-DA2QKR-400-A-Z0-A)
Action level Failure code CAN2 Disconnection (Pump Controller)

Failure
L03 DA2QKR (Detected by machine monitor) (Machine monitor system)
Detail of • Machine monitor does not recognize pump controller through CAN communication 2 line
failure (KOMNET/c).
Action of
• Holds information at the time of occurrence of failure.
controller
• Information to be obtained from pump controller is not displayed or special function that
Problem on uses information from pump controller does not work. Or received data (failure codes,
machine monitoring codes, etc. transmitted from pump controller) is no longer updated.
switch is received.
• If any of failure codes [DY20KA], [DY20MA] or [DW43KA] is displayed, pump controller
may be defective.
whether air conditioner is operated (ON/OFF and air flow adjustment) on air conditioner
Related screen.
number of failure codes that may be generated is four; [DA2QKR], [DB2QKR], [D8AQKR],
and [DAZQKR].
a Air conditioner can be operated even when failure code is displayed on machine monitor
screen. If air conditioner is operated, there is no possibility of ground fault, short circuit, or
hot short circuit in wiring harness (CAN communication line).
• Since each controller and machine monitor are connected to continuous power supply,
they receive continuous power even while starting switch is at OFF position.
using multimeter.
2. Disconnect fusible link F05 and connect T-adapters to female side.
1 Defective fusible link F05 Resis- Between F05 (female) (1) and (2)
Max. 1 z
tance
a If fusible link is blown, circuit may have ground fault.
Defective fuse No. 17 in fuse
2 2. Remove fuse No. 17 in fuse box F01.
box F01
If fuse is blown, circuit probably has ground fault.
a Check ground terminal T04 for looseness and rust.
Improper power supply to 2. Disconnect connector CP01 and connect T-adapter to female side.
3 pump controller 3. Turn starting switch to ON position.
Between CP01 (female) (1) and (2) 20 to 30 V
Voltage
Between CP01 (female) (4) and (5) 20 to 30 V
40-420 PC360LC-10
40 Troubleshooting

Open circuit in wiring harness 2. Remove fuse No. 17 in fuse box F01.
3. Disconnect connectors F05 and CP01, and connect T-adapters to
Between terminal R04 and F05 (female) (1) Max. 1 z
Resis- Between F05 (female) (2) and F01-16F Max. 1 z
tance Between F01-17 and CP01 (female) (1) Max. 1 z
Between F01-17 and CP01 (female) (4) Max. 1 z
Defective CAN Perform checks on cause 4 to 9 in troubleshooting for failure code
5 [DB2QKR].
communication 2 line
PC360LC-10 40-421
40 Troubleshooting
Circuit diagram related to pump controller power supply
40-422 PC360LC-10
40 Troubleshooting
Failure code [DA2RKR] CAN1 Discon ( Pump Con) (PC400-DA2RKR-400-A-Z0-A)
Action level Failure code CAN1 Disconnection ( Pump Controller)

Failure
L03 DA2RKR (Detected by machine monitor) (Machine monitor system)
Detail of • Machine monitor does not recognize pump controller through CAN communication line 1
failure (KOMNET/r).
• Retains current working mode.
Action of • Retains current selection of auto-deceleration.
controller • Retains current setting (Hi/Lo) of travel speed.
• Information to be obtained from pump controller is not displayed or special function that
uses information from pump controller does not work. Or received data is no longer
updated.
Problem on • Pump control is disabled.
machine • Hydraulic oil temperature gauge needle goes off on machine monitor screen.
• Wiper operation is disabled.
• Washer operation is disabled.
• Flow control of attachment hydraulic line is disabled.
switch is received.
• If any of failure codes [DY20KA], [DY20MA] or [DW43KA] is also displayed, pump
controller may be defective.
• Machine monitor indicates CAN communication failure with failure codes [DA2RKR] or
[DB2RKR]. If failure code [DB2RKR] is also displayed, wiring harness (CAN
Related communication line) may have ground circuit, short circuit, or hot short circuit.
information • Terminating resistor of CAN1 on cab side is inside machine monitor, and that on engine
side is connector "B_RES". (Connector "B_RES" is not on CAN communication 1 line but
connected to it via connector "J2").
• Since signal of active CAN communication line is pulse voltage, it cannot be measured by
using multimeter.
Defective pump controller Perform checks on causes 1 to 4 in troubleshooting for failure code
1 power supply system [DA2QKR].
Defective CAN Perform checks on causes 2 to 8 in troubleshooting for failure code
2 communication 1 system [DB2RKR].
PC360LC-10 40-423
40 Troubleshooting
Failure code [DAF0MB] Monitor ROM Abnormality (PC400-DAF0MB-400-A-Z0-A)
Action level Failure code Monitor ROM Abnormality

Failure
– DAF0MB (Machine monitor system)
Detail of • Program of machine monitor is rewritten (program error).
failure
Action of
controller
Problem on • Indication of machine monitor is unreliable.
machine • Machine monitor is incapable of normally exchanging data with controllers.
information
Machine monitor is defective.
40-424 PC360LC-10
40 Troubleshooting
Failure code [DAF0MC] Monitor Error (PC400-DAF0MC-400-A-Z0-A)
Action level Failure code Monitor Error

Failure
– DAF0MC (Machine monitor system)
Detail of
• Machine monitor malfunctions.
failure
Action of
controller
Problem on • Indication of machine monitor is unreliable.
machine • Machine monitor is incapable of normally exchanging data with controllers.
information
Machine monitor is defective.
PC360LC-10 40-425
40 Troubleshooting
Failure code [DAF8KB] Camera Power Supply Short Circuit (PC400-DAF8KB-400-A-Z0-

A)
Action level Failure code Camera Power Supply Short Circuit

Failure
L03 DAF8KB (Machine monitor system)
Detail of • Output power supply voltage (rating: 8 V) from machine monitor to camera is below 6.0 V
failure or above 10 V.
Action of • Stops output power supply voltage (rating: 8 V) to camera.
machine • Even if cause of failure disappears, machine does not become normal until starting switch
monitor is turned to OFF position.
Problem on • Camera image is not displayed on monitor screen.
machine
information
Cause Procedure, measuring location, criteria and remarks

2. Disconnect camera connector A45, and turn starting switch to ON
Defective camera position.
1
After above operation (disconnecting camera connector and performing
failure code reproducing procedure), if failure code disappears, camera
has internal defect.
2. Disconnect connector CM04.
2 Defective machine monitor 3. Connect T-adapters to male side of connector CM04.
Voltage Between CM04 (male) (1) and ground 6 to 10 V
Ground fault in wiring harness 2. Disconnect connector CM04 and camera connector A45.
3 3. Connect T-adapters to female side of connector CM04.
Resis- Between CM04 (female) (1) and ground
Min. 1 Mz
tance
2. Disconnect camera connector A45.
Hot short circuit in wiring 3. Insert T-adapters into connector CM04.
(contact with 24 V circuit) (Disconnect camera and check that camera is not defective in
advance.)
Voltage Between CM04 (1) and (5) Max. 10 V
40-426 PC360LC-10
40 Troubleshooting
Circuit diagram related to camera power supply
PC360LC-10 40-427
40 Troubleshooting
Failure code [DAF9KQ] Model Selection Abnormality (PC400-DAF9KQ-400-A-Z0-A)
Action level Failure code Model selection abnormality

Failure
L03 DAF9KQ (Machine monitor system)
Detail of • Model registered in the machine monitor and pump controller differs.
failure (Machine monitor or pump controller has been replaced with a wrong part.)
Action of
controller
Problem on • Machine does not operate normally.
machine
• Assembly part No. of pump controller program can be checked by using monitoring
function (Code: 20229)
Related • Assembly part No. of machine monitor program can be checked by using monitoring
information function (Code: 20227)
1. Use monitoring function to display assembly part number and check
whether it is identical to that listed in Parts book.
1 Defective machine monitor Defective machine monitor
(a different model is registered)
1. Use monitoring function to display assembly part number and check
whether it is identical to that listed in Parts book.
Defective pump controller
40-428 PC360LC-10
40 Troubleshooting
Failure code [DAFGMC] GPS Module Error (PC400-DAFGMC-400-A-Z0-A)
Action level Failure code GPS Module Error

Failure
– DAFGMC (KOMTRAX system in machine monitor)
Detail of • Position data is not sent from GPS module (in machine monitor) to KOMTRAX
failure communication modem in 50 seconds after KOMTRAX started.
monitor
Problem on
machine
Related • Method of reproducing failure code: Turn starting switch to ON position (wait at least 50
information seconds after starting switch is turned to ON position).
GPS module in machine monitor may be defective.
PC360LC-10 40-429
40 Troubleshooting
Failure code [DAFLKA] Operating Lamp Open Circuit(Monitor) (PC300-DAFLKA-

400-A-Z0-A)
Action level Failure code Operating Lamp Open Circuit (Monitor)

Failure
- DAFLKA (Machine monitor system)
• Machine monitor determines that system operating lamp circuit is open because voltage
Detail of of output circuit remains at approximately 5 V or less for approximately 3 seconds after
failure starting switch is turned to ON position, during which machine monitor outputs no current
to system operating lamp.
controller
Problem on position. Setting battery disconnect switch to OFF position may destroy data stored in
machine machine monitor terminal memory.
• Although machine monitor is not able to light system operating lamp, no trouble will result
Related unless battery disconnect switch is turned to OFF position.
1

3. Disconnect connectors CM01 and L19, and connect T-adapters to each
defective contact of Between CP02 (female) (100) and L19 (female) (2) Max. 1 z
Defective machine If no failure is found by above checks, machine monitor is defective. (Since
monitor
40-430 PC360LC-10
40 Troubleshooting
PC360LC-10 40-431
40 Troubleshooting
Failure code [DAFLKB] System Operating Lamp Short Circuit

(Monitor) (PC300-DAFLKB-400-A-Z0-A)
Action level Failure code Operating Lamp Short Circuit (Monitor)
Failure
- DAFLKB (Machine monitor system)
• Machine monitor determines that system operating lamp circuit shorts because voltage of
Detail of output circuit does not become low level while machine monitor outputs current to system
failure operating lamp.
controller
Problem on position. Setting battery disconnect switch to OFF position may destroy data stored in
machine machine monitor terminal memory.
Related • Although machine monitor is not able to light system operating lamp, no trouble will result
information unless battery disconnect switch is turned to OFF position.
1
Defective machine If no failure is found by above checks, machine monitor is defective. (Since
monitor
40-432 PC360LC-10
40 Troubleshooting
Failure code [DAFQKR] CAN2 Discon (Monitor) (PC400-DAFQKR-400-A-Z0-A)
Action code Failure code CAN2 Disconnection (Monitor)

Failure
- DAFQKR (KOMTRAX system)
Detail of • KOMTRAX terminal does not recognize machine monitor through CAN communication 2
failure line.
Action of
controller
Problem on • System may not function normally.
machine
switch is received.
• Failure code is transmitted to and displayed on machine monitor by CAN communication.
Accordingly, if CAN communication with machine monitor fails, failure code [DAFQKR] is
Related not displayed on machine monitor and it can be observed only through KOMTRAX
information system.
• Since each controller and machine monitor are connected directly to battery, they are
supplied with power even after starting switch is turned to OFF position.
• Since signal of active CAN communication line is pulse voltage, it cannot be measured by
using multimeter.
Defective power supply Perform troubleshooting for "E-5" in E mode troubleshooting.
1
to machine monitor
Defective CAN Perform checks on causes 4 and after in troubleshooting for failure code
2 [DB2QKR]
communication
PC360LC-10 40-433
40 Troubleshooting
Failure code [DAZ9KQ] AC Model Selection Abnormality (PC400-DAZ9KQ-400-A-Z0-A)
Action level Failure code Air Conditioner Model Selection Abnormality

Failure
– DAZ9KQ (Machine monitor system)
Detail of • Model registered in the machine monitor and air conditioner controller differs.
failure (Machine monitor or air conditioner controller has been replaced with a wrong part.)
Action of
controller
Problem on • Machine does not operate normally.
machine
• Model code registered in air conditioner controller can not be checked by using
• Model codes registered in machine monitor can be checked by using monitoring function.
(Code: 00500)
Related • Air conditioner control data (series and model) in the machine monitor can be checked by
information using monitoring function. (Code: 55200)
• Air conditioner control data (series and model) in the air conditioner controller can be
checked by using monitoring function. (Code: 55201) (It is normal if control data is 01H
(which means PC).)
Defective machine monitor
Defective air conditioner Defective air conditioner controller
2
controller (a different model is registered)
40-434 PC360LC-10
40 Troubleshooting
Failure code [DAZQKR] CAN2 Discon (AC) (PC400-DAZQKR-400-A-Z0-A)
Action level Failure code CAN2 Disconnection (Air Conditioner)

Failure
L01 DAZQKR (Detected by machine monitor) (Machine monitor system)
Detail of • In CAN communication 2 line (KOMNET/c), machine monitor cannot recognize air
failure conditioner controller.
Action of
controller
• Function to collect information from engine controller does not work.
Problem on codes sent from engine controller)
machine • Air conditioner will be inoperable.
• Air conditioner control screen will not be displayed correctly on the machine monitor.
switch is received.
• When the machine monitor detects a CAN communication error in CAN2, failure code
[DA2QKR], [DB2QKR], [D8AQKR], or [DAZQKR] becomes active. If all four of these
failure code are displayed, there is a possibility of short circuit to ground, another circuit,
or positive side of battery in the harness (CAN communication line).
Related
and [DAZQKR].
using multimeter.
Defective power supply to air a Perform troubleshooting in Chapter 80 "Troubleshooting for power
1
conditioner controller supply system".
Defective CAN terminating 1. Turn starting switch to OFF position.

resis- 2. Disconnect connectors CM02 and K02, and connect T-adapters to
2 each male side.
tor (internal open or short
circuit) Resis- Between K02 (male) (A) and (B) 120 ± 12 z
tance Between CM02 (male) (7) and (9) 120 ± 12 z
PC360LC-10 40-435
40 Troubleshooting

• CAN communication line
a Machine monitor also has 120 z CAN terminating resistor in it. Since
120 z resistors are connected in parallel, if resistance measured at
connector of controller other than machine monitor is 60 z which is
combined resistance, there is no open circuit in wiring harness.
2. Disconnect related connectors and connect T-adapters to connector
at which measurement is performed.
a If short circuit occurs (if resistance between terminals is 1 z or less),
disconnect CAN communication connectors of all controllers. Then,
check whether short circuit is in wiring harnesses or within controller.
3 Approx.
harness Between CM02 (female) (8) and (9)
120 z
Between CE03 (female) (17) and (18) Approx. 60
z
Between CP01 (female) (45) and (64) Approx. 60
z
Resis- Between AC01 (female) (1) and (2) Approx. 60
tance z
Between CK01 (female) (10) and (11) Approx. 60
z
*Between CC01 (female) (10) and (11) Approx. 60
z
Between K02 (female) (A) and (B) Approx.
120 z
40-436 PC360LC-10
40 Troubleshooting

• ACC signal from starting switch (CAN communication start is not
sensed)
2. Disconnect connector at which measurement is performed and
insert T-adapters into it.
3. Turn battery disconnect switch to ON position, and turn starting
Between CM01 (10) and (3) 20 to 30 V
Between CP01 (24), (43), (80) and (2) 20 to 30 V
Voltage
Between AC02 (4) and (1) 20 to 30 V
Between CK02 (3) and (1) 20 to 30 V
*Between CC01 (2) and (7) 20 to 30 V
2. Disconnect related connectors and connect T-adapters to female
side of connector at which measurement is performed.
Between CM02 (female) (8) and CP01 (female)
Open circuit in wiring harness (45) Max. 1 z
4 (wire breakage or defective Between CM02 (female) (9) and CP01 (female)
contact of connector) (64) Max. 1 z
Between CM02 (female) (8) and CE03 (female)
(17) Max. 1 z
(18) Max. 1 z
Between CM02 (female) (8) and AC01 (female)
(1) Max. 1 z
Max. 1 z
Resis- (2)
tance Between CM02 (female) (8) and CK01 (female)
(10) Max. 1 z
Between CM02 (female) (9) and CK01 (female)
(11) Max. 1 z
Between CM02 (female) (8) and CC01 (female)
(3) Max. 1 z
(9) Max. 1 z
Between CE03 (female) (17) and K02 (female)
(A) Max. 1 z
(B) Max. 1 z
PC360LC-10 40-437
40 Troubleshooting

a If no failure is found by checks on cause 3 (no open circuit), measure
voltage at one connector.
Ground fault in wiring harness 2. Disconnect related connectors and connect T-adapters to female
5
(contact with ground circuit) side of connector at which measurement is performed.
Between CP01 (female) (45), CM02 (female)
Min. 1 Mz
Resis- (7), (8), or CE03 (female) (17) and ground
tance Between CP01 (female) (64), CM02 (female)
(9), or CE03 (female) (18) and ground Min. 1 Mz

insert T-adapters into connector.
3. Turn the battery disconnect switch to the ON position.
Short circuit or hot short 4. Turn starting switch to ON position.
circuit in wiring harness a Since voltages of CAN H and CAN L lines are 2.5 ± 1 V including
6 (contact with 24 V during communication, harnesses are considered normal as long as
circuit) their voltages are between 1 and 4 V.
Between ground and any one of CM02 (female)
(8), CP01 (female) (45), CK01 (female) (10),
AC01 (female) (2), CC01 (female) (3), or CE03 1 to 4 V
(female) (17)
Voltage
(female) (18)
• If all four failure codes [DA2QKR], [DB2QKR], [D8AQKR], and
[DAZQKR] are displayed
a Repeat following steps 1. to 3. to disconnect controllers one by one
from CAN communication and to identify defective controller.
Defective engine controller, switch to OFF position.
pump controller, air 2. Disconnect CAN communication connector of engine controller
7 conditioner unit, *ID (connector CE03), pump controller (connector CP01), air conditioner
controller, or KOMTRAX unit (connector AC01), *ID controller (connector CC01), and
terminal KOMTRAX terminal (connector CK01) one by one.
3. Turn battery disconnect switch to ON position, turn starting switch to
ON position, then perform troubleshooting.
4. Return to step 1. and troubleshoot next controller.
Has the number of displayed failure codes If YES, disconnected
decreased from four? controller is defective.
If no abnormality is found by above diagnosis, air conditioner controller
Defective air conditioner is defective.
8
controller
*The ID controller is an optional device.
40-438 PC360LC-10
40 Troubleshooting
Circuit diagram related to CAN communication 2
PC360LC-10 40-439
40 Troubleshooting
Failure code [DB2QKR] CAN2 Discon (Engine Con) (PC400-DB2QKR-400-A-Z0-A)
Action level Failure code CAN2 Disconnection (Engine Controller)

Failure
L03 DB2QKR (Detected by machine monitor) (Machine monitor system)
Detail of • Machine monitor cannot recognize engine controller through CAN communication 2 line
failure (KOMNET/c).
Action of
controller
• Information to be obtained from engine controller is not displayed and special functions
Problem on that use them do not work. Or, received data is no longer updated. (such as failure codes
machine and monitoring
codes sent from engine controller)
switch is received.
• If failure code [DB2RKR] is also displayed, engine controller may be defective (cause 2).
• ID controller is optional device (connector CC01)
whether air conditioner is operated (ON/OFF and air flow adjustment) on air conditioner
Related screen.
and [DAZQKR].
a Air conditioner can be operated even when failure code is displayed on machine monitor
screen. If air conditioner is operated, there is no possibility of ground fault, short circuit, or
hot short circuit in harness (CAN communication line).
using multimeter.
Defective fuses Nos. 15 and
1 2. Remove fuses No. 15 and No. 18 from fuse box F01.
18 in fuse box F01
• When fuse is blown, engine controller may have short circuit in it.
a If fuse is not blown, this check is not required.
2 Defective engine controller 2. Disconnect connector CE03 and connect T-adapters to male side.
Resis- Between CE03 (male) (1) and (21) Min. 10 z
tance Between CE03 (male) (11) and (31) Min. 10 z
a Check ground terminal T12 for looseness and rust.
Improper power supply to 3. Turn starting switch to ON position.
3 engine controller
a If result is abnormal, perform troubleshooting for [CA441].
Between CE03 (female) (1) and (21) 20 to 30 V
Voltage
Between CE03 (female) (11) and (31) 20 to 30 V
resis- 2. Disconnect connectors CM02 and K02, and connect T-adapters to
4 each male side.
tor (internal open or short
circuit) Resis- Between K02 (male) (A) and (B) 120 ± 12 z
40-440 PC360LC-10
40 Troubleshooting

2. Disconnect related connectors and connect T-adapters to connector
at which measurement is performed.
disconnect CAN communication connectors of all controllers. Then,
check whether short circuit is in wiring harnesses or within controller.
5 Approx.
harness Between CM02 (female) (8) and (9)
120 z
Between CE03 (female) (17) and (18) Approx. 60
z
z
Resis- Between AC01 (female) (1) and (2) Approx. 60
tance z
Between CK01 (female) (10) and (11) Approx. 60
z
*Between CC01 (female) (10) and (11) Approx. 60
z
Between K02 (female) (A) and (B) Approx.
120 z
sensed)
insert T-adapters into it.
Open circuit in wiring harness Between CE03 (3) and (21) 20 to 30 V
6 (wire breakage or defective Between CP01 (24), (43), (80) and (2) 20 to 30 V
contact of connector) Voltage
Between AC02 (4) and (1) 20 to 30 V
Between CK02 (3) and (1) 20 to 30 V
*Between CC01 (2) and (7) 20 to 30 V
side of connector at which measurement is performed.
PC360LC-10 40-441
40 Troubleshooting

(45) Max. 1 z
(64) Max. 1 z
(17) Max. 1 z
(18) Max. 1 z
(1) Max. 1 z
Open circuit in wiring harness Max. 1 z
Resis- (2)
6 (wire breakage or defective tance Between CM02 (female) (8) and CK01 (female)
contact of connector) Max. 1 z
(10)
Between CM02 (female) (9) and CK01 (female)
(11) Max. 1 z
(3) Max. 1 z
(9) Max. 1 z
(A) Max. 1 z
(B) Max. 1 z

Ground fault in wiring harness side of connector at which measurement is performed.
7
(contact with ground circuit) Between ground and any point in CP01
(female) (45), CM02 (female) (7), (8) or CE03 Min. 1 Mz
Resis- (female) (17)
tance Between ground and any point in CP01
(female) (64), CM02 (female) (9) or CE03 Min. 1 Mz
(female) (18)
40-442 PC360LC-10
40 Troubleshooting

a If no failure is found by check on cause 5 (no open circuit), measure
in only one place each.
insert T-adapters into connector.
circuit in wiring harness a Since voltages of CAN H and CAN L lines are 2.5 ± 1 V including
8 (contact with 24 V during communication, harnesses are considered normal as long as
circuit) their voltages are between 1 and 4 V.
(female) (17)
Voltage
(female) (18)
• If all four failure codes [DA2QKR], [DB2QKR], [D8AQKR], and
[DAZQKR] are displayed
a Repeat following steps 1. to 3. to disconnect controllers one by one
from CAN communication and to identify defective controller.
Defective engine controller, switch to OFF position.
pump controller, air 2. Disconnect CAN communication connector of engine controller
9 conditioner unit, *ID (connector CE03), pump controller (connector CP01), air conditioner
controller, or KOMTRAX unit (connector AC01), *ID controller (connector CC01), and
terminal KOMTRAX terminal (connector CK01) one by one.
3. Turn battery disconnect switch to ON position, turn starting switch to
ON position, then perform troubleshooting.
4. Return to step 1. and troubleshoot next controller.
Has the number of displayed failure codes If YES, disconnected
decreased from four? controller is defective.
*The ID controller is an optional device.
PC360LC-10 40-443
40 Troubleshooting
40-444 PC360LC-10
40 Troubleshooting
Failure code [DB2RKR] CAN1 Discon (Engine Con) (PC300-DB2RKR-400-A-Z0-A)
Action level Failure code CAN1 Disconnection (Engine Controller)

Failure
L03 DB2RKR (Detected by machine monitor) (Machine monitor system)
Detail of • Machine monitor does not recognize engine controller through CAN communication 1 line
failure (KOMNET/r).
• Retains current working mode.
Action of
• Retains current selection of auto-deceleration.
controller
• Information to be obtained from engine controller is not displayed and special functions
that use them do not work. Or, received data is no longer updated. (such as failure codes
and monitoring
Problem on
• Engine cannot be controlled.
machine
• Engine speed and coolant temperature cannot be detected.
• Engine coolant and hydraulic oil temperature gauge needles go off on machine monitor
screen.
switch is received.
• If failure code [DB2QKR] is also displayed, engine controller may be defective (cause 1).
• Machine monitor uses failure codes [DB2RKR] or [DA2RKR] to indicate failure in CAN
communication through CAN communication 1 line. If failure code [DA2RKR] is also
displayed, wiring harness (CAN communication line) may have ground fault, short circuit
Related or hot short circuit.
information • CAN1 terminating resister is located in machine monitor on operator's cab side and
connector "RES2" is located on engine side (CAN communication-1 circuit (KOMNET/r) is
not provided. It is output from connector "ECM J2".)
using multimeter.
Defective engine controller [Perform checks on causes 1 to 3 in troubleshooting for failure code
1 system [DB2QKR].
resistor 2. Disconnect connectors CM02 and RES2, and connect T-adapters to
2 male side of them.
(internal open circuit or short
circuit) Resis- Between RES2 (male) (A) and (B) 120 ± 12 z
PC360LC-10 40-445
40 Troubleshooting

2. Disconnect connectors CM02, CP01, ECM J1, ECM J2 and RES2
one by one, and connect T-adapters to each female side.
Open or short circuit in wiring disconnect all CAN communication connectors of each controller.
3
harness Then, check whether short circuit is in wiring harness or within
controller.
Between CM02 (female) (11) and (12) Approx.
120 z
z
Resis- Between RES2 (female) (A) and (B) Approx.
tance 120 z
Between ECM J1 (female) (8) and (18) Approx.
120 z
Between ECM J2 (female) (24) and (25) Approx.
120 z
recognized)
2. Disconnect CM01, CP01, CE03 and insert T-adapters.
Voltage Between CE03 (3) and (21) 20 to 30 V
Between CP01 (24), (43), (80) and (2) 20 to 30 V
Open circuit in wiring harness switch to OFF position.
4 (wire breakage or defective 2. Disconnect connectors CM02, CP01, ECM J1, ECM J2 and RES2,
contact of connector) and connect T-adapters to each female side.
Between CM02 (female) (11) and CP01
Between CM02 (female) (12) and CP01
Between CM02 (female) (11) and ECM J1
Max. 1 z
Resis- (female) (8)
tance Between CM02 (female) (12) and ECM J1
Between ECM J2 (female) (24) and RES2
(female) (A) Max. 1 z
Between ECM J2 (female) (25) and RES2
(female) (B) Max. 1 z
40-446 PC360LC-10
40 Troubleshooting

2. Disconnect connectors CM02, CP01, ECM J1, ECM J2 and RES2,
and connect T-adapters to any one of female sides.
Between ground and any one of CP01 (female)
(7), CM02 (female) (10), (11), or ECM J1 Min. 1 Mz
Ground fault in wiring harness (female) (8)
5
(contact with ground circuit) Between ground and ECM J2 (female) (24) or
Min. 1 Mz
Resis- RES2 (female) (A)
tance Between ground and any one of CP01 (female)
(26), CM02 (female) (12), or ECM J1 (female) Min. 1 Mz
(18)
Between ground and either of ECM J2 (female)
(25) and RES2 (female) (B) Min. 1 Mz
a If no failure (no open circuit) is found by check on cause 3, measure

2. Disconnect any one of connectors CM02, CP01, and RES2, and
connect T-adapters to female side of connector disconnected.
circuit in wiring harness
6 (contact with 24 V a Measurement is not performed on ECM J1 and ECM J2.
(contact with 24 V circuit) a Since voltages of CAN H and CAN L lines are 2.5 ± 1 V including
during communication, harnesses are considered normal as long as
their voltages are between 1 and 4 V.
(7), CM02 (female) (10), (11), or RES2 (female) 1 to 4 V
Voltage (A)
(26), CM02 (female) (12), or RES2 (female) (B) 1 to 4 V
• If failure code [DA2RKR] is also displayed
a Disconnect pump controller and engine controller one by one from
CAN communication line to determine which controller is defective.
7 Defective pump controller switch to OFF position.
2. Disconnect pump controller (connector CP01).
Does either or both of failure codes [DA2RKR] If YES, pump controller
and [DB2RKR] disappear? is defective.
• If failure code [DA2RKR] is also displayed
a Disconnect pump controller and engine controller one by one from
CAN communication line to determine which controller is defective.
8 Defective engine controller switch to OFF position.
2. Disconnect engine controller (connector ECM J1).
Does either or both of failure codes [DA2RKR] If YES, engine
and [DB2RKR] disappear? controller is defective.
PC360LC-10 40-447
40 Troubleshooting
40-448 PC360LC-10
40 Troubleshooting
Failure code [DGH2KB] Hyd Oil Sensor Short Circuit (PC400-DGH2KB-400-A-Z0-A)
Action level Failure code Hydraulic Oil Sensor Short Circuit

Failure
L01 DGH2KB (Pump controller system)
Detail of • Signal voltage of hydraulic oil temperature sensor circuit is below 1 V, so pump controller
failure determines that circuit has ground fault.
Action of • If cause of failure disappears, machine becomes normal by itself.
controller
Problem on • Hydraulic oil temperature gauge indicates 50°C.
machine
• Signal voltage from hydraulic oil temperature sensor can be checked with monitoring
Related function.
information (Code: 04402 Hydr. Temp. Sensor Volt)
Approx. 90
10°C
kz
Defective hydraulic oil Between P22 (male) (1) and (2) Approx. 35
1 temperature sensor 30°C
kz
(Internal open or short circuit) Resis- a Temperature-resistance Approx. 6.5
tance characteristics of oil 80°C
temperature sensor kz
Approx. 3.5
100°C
kz
Between P22 (male) (2) and ground Min. 1 Mz
2. Disconnect connector P22 and connect T-adapter to female side.
Open circuit, short circuit, a If voltage is 0 V, wiring harness has open circuit, ground fault, or
2 ground fault, or hot short short circuit, and if voltage is 24 V, wiring harness has hot short
circuit in wiring harness circuit.
a Voltage of approximately 5 V is applied to temperature sensor signal
circuits through resistance in pump controller.
Voltage Between P22 (female) (1) and (2) Approx. 5 V
2. Disconnect connector CP01 and connect T-adapter to female side.
a Use Temperature-Resistance characteristics table for
Short circuit or ground fault in troubleshooting on cause 1 as resistance criteria.
3 wiring harness
a If resistance is 1 Mz or higher, wiring harness has open circuit. If
resistance is 1 z or below, wiring harness has short circuit.
Resis- Between CP01 (female) (28) and (46) 3.5 to 90 kz
tance Between CP01 (female) (28) and ground Min. 1 Mz
4 2. Disconnect connectors CP01 and P22, and connect T-adapter to
(Contact with ground circuit) either female side.
Resis- Between ground and CP01 (female) (28) or
tance
If cause is not found by above checks, pump controller is defective.
PC360LC-10 40-449
40 Troubleshooting
Circuit diagram related to hydraulic oil temperature sensor
40-450 PC360LC-10
40 Troubleshooting
Failure code [DHA4KA] Air Cleaner Clogging Sensor Open Circuit (PC400-
DHA4KA-400-A-Z0-A)
Action level Failure code Air Cleaner Clogging Sensor Open Circuit
Failure
L01 DHA4KA (Machine monitor system)
Detail of • Air cleaner clogging switch signal voltage is not below 1 V while engine is running, so
failure machine monitor determines that air cleaner is clogged (switch contact is open).
Action of • Displays air cleaner clogging monitor in red on machine monitor.
controller
Problem on • If machine is used as it is, engine may be broken.
machine
• Input signal status (ON/OFF) from air cleaner clogging switch can be checked by using
Related monitoring function (Code: 04501 Monitor input: 2).
Clogged air cleaner
Air cleaner may be clogged. Check it for clogging and then clean or replace if
1 (when system is
clogged.
normal)
Defective air cleaner
2 clogging switch (Internal When air cleaner is
Max. 1 z
open circuit) Between P23 (male) (1) normal *1
Resistance and (2) When air cleaner is
clogged *2 Min. 1 Mz
harness 2. Disconnect connectors CM02 and P23, and connect T-adapters to each
3 (wire breakage or female side.
defective contact of Between CM02 (female) (4) and P23 (female) (1) Max. 1 z
Between P23 (female) (2) and ground Max. 1 z
2. Insert T-adapters into connectors CM01 and CM02.
Defective machine
4 When air cleaner is
monitor Max. 1 V
Between CM02 (4) and normal
Voltage
CM01 (3) When air cleaner is
clogged Min. 10 V
• Air cleaner suction resistance

*1: Max. -3,430 Pa {-350 mmH2O}
*2: -7,470 ± 490 Pa {-762 ± 50 mmH2O}
PC360LC-10 40-451
40 Troubleshooting
Circuit diagram related to air cleaner clogging
40-452 PC360LC-10
40 Troubleshooting
Failure code [DHPAMA] Pump Press Sensor Abnormality (PC400-DHPAMA-400-A-Z0-A)
Action level Failure code Pump Pressure Sensor Abnormality

Failure
L01 DHPAMA (Pump controller system)
Detail of • Signal voltage of front pump pressure sensor circuit is below 0.3 V or above 4.5 V.
failure
Action of • Controls machine taking it that front pump pressure is 0 MPa {0 kg/cm 2 }.
Problem on • Automatic travel speed selector function does not work.
machine • Straight travel performance or steering performance lowers.
a If 5 V circuit (3) and ground circuit (1) of pressure sensor are connected inversely,
pressure sensor will be broken. Accordingly, take extreme care when checking.
• Front pump pressure can be checked with monitoring function.
(Code: 01100 F pump pressure).
If failure code [DA25KP] is also displayed, perform troubleshooting for it
first.
Defective 5V sensor power 2. Disconnect connector P25, and connect T-adapters to female side.
1 supply 1 system 3. Turn starting switch to ON position.
a If power supply voltage is abnormal, proceed to check on cause 3.
Power 4.5 to 5.5
supply V
2. Insert T-adapters into connector P25.
Sensor 0.5 to 4.5
Voltage Between P25 (2) and (1)
output V
a If power supply voltage is normal and sensor output voltage is
abnormal, it is difficult to judge whether cause of failure is defective
Defective front pump sensor, ground fault or hot short circuit in wiring harness. Check as
2 pressure sensor (internal below.
defect)
2. Replace connector P25 with connector P26 of R pump PPC
pressure sensor.
3. Turn starting switch to ON position and display "Abnormality Record"
screen of electrical system on machine monitor.
4. If E mark is not displayed for this failure code, front pump pressure
a After finishing test, restore connectors.
PC360LC-10 40-453
40 Troubleshooting

2. Disconnect connectors CP01 and P25, and connect T-adapters to
each female side.
a If power supply voltage measured in check
on cause 1 is normal, this check is not
required. Max. 1 z
Open circuit in wiring harness Between CP01 (female) (18) and P25 (female)
3 (wire breakage or defective (1)
contact of connector) Resis- Between CP01 (female) (11) and P25 (female)
(2) Max. 1 z
tance
required. Max. 1 z
Between CP01 (female) (6) and P25 (female)
(3)
Ground fault in wiring harness 2. Disconnect connectors C01 and P25, and connect T-adapters to
Resis- Between ground and CP01 (female) (11) or P25
(female) (2) Min. 1 Mz
tance
5 harness 3. Connect T-adapters to female side of connector P25.
(contact with 5 V/24 V circuit) 4. Turn starting switch to ON position.
40-454 PC360LC-10
40 Troubleshooting
Circuit diagram related to front pump pressure sensor
PC360LC-10 40-455
40 Troubleshooting
Failure code [DHPBMA] R Pump Press Sensor Abnormality (PC400-DHPBMA-400-A-

Z0-A)
Action level Failure code Rear Pump Press Sensor Abnormality

Failure
L01 DHPBMA (Pump controller system)
Detail of • Signal voltage of rear pump pressure sensor circuit is below 0.3 V or above 4.5 V.
failure
Action of • Controls machine taking it that rear pump pressure is 0 MPa {0 kg/cm2 }.
Problem on • Automatic travel speed selector function does not work.
machine • Straight travel performance or steering performance lowers.
• Rear pump pressure can be checked with monitoring function.
(Code: 01101 R pump pressure)
first.
Power 4.5 to 5.5
supply V
2. Connect T-adapters to connector P26.
Sensor 0.5 to 4.5
output V
Defective rear pump pressure sensor, ground fault or hot short circuit in wiring harness. Check as
2 sensor (internal defect) below.
2. Replace connector P26 with connector P25 of front pump PPC
pressure sensor.
4. If E mark is not displayed for this failure code column, rear pump
40-456 PC360LC-10
40 Troubleshooting

each female side.
required. Max. 1 z
(2) Max. 1 z
tance
required. Max. 1 z
(3)
Ground fault in wiring harness 2. Disconnect connectors CP01 and P26, and connect T-adapters to
tance
PC360LC-10 40-457
40 Troubleshooting
Circuit diagram related to rear pump pressure sensor
40-458 PC360LC-10
40 Troubleshooting
Failure code [DHS3MA] Arm IN PPC Sen. Abnormality (PC300-DHS3MA-400-A-Z0-A)
Action level Failure code Arm IN PPC Sensor. Abnormality

Failure
L01 DHS3MA (Pump controller system)
Detail of • Signal voltage of arm IN PPC pressure sensor circuit is below 0.3 V or above 4.5 V.
failure
Action of • Controls machine taking it that arm IN PPC pressure is 0 MPa {0 kg/cm 2 }.
Problem on • Automatic deceleration does not cancel.
machine • Controllability of arm IN deteriorates.
• Arm IN PPC pressure can be checked with monitoring function.
(Code: 07200 Arm IN PPC pressure)
first.
Defective 5V sensor power 2. Disconnect connector P04 and connect T-adapters to female side.
Power 4.5 to 5.5
supply V
Sensor 0.5 to 4.5
output V
Defective arm IN PPC sensor, ground fault or hot short circuit in wiring harness. Check as
defect)
2. Replace connector P04 with connector of other PPC pressure
sensor.
4. If E mark is not displayed again for this failure code, arm IN PPC
PC360LC-10 40-459
40 Troubleshooting

each female side.
required. Max. 1 z
(2) Max. 1 z
tance
required. Max. 1 z
(3)
Ground fault in wiring harness 2. Disconnect connectors CP01 and P04, and connect T-adapter to
tance
Circuit diagram related to arm IN PPC pressure sensor
40-460 PC360LC-10
40 Troubleshooting
Failure code [DHS4MA] Bucket CURL PPC Press Sensor

Abnormality (PC300-DHS4MA-400-A-Z0-A)
Action level Failure code Bucket CURL PPC Pressure Sensor Abnormality
Failure
Detail of • Signal voltage of bucket CURL PPC pressure sensor circuit is below 0.3 V or above 4.5 V.
failure
Action of • Controls machine taking it that bucket CURL PPC pressure is 0 MPa {0 kg/cm 2 }.
machine • Controllability of bucket CURL deteriorates.
• Bucket CURL PPC pressure can be checked with monitoring function.
(Code: 07300 Bucket CURL PPC pressure)
first.
Power 4.5 to 5.5
supply V
Sensor 0.5 to 4.5
output V
Defective bucket CURL PPC sensor, ground fault or hot short circuit in wiring harness. Check as
defect)
sensor.
4. If E mark is not displayed again for this failure code, bucket CURL
PPC pressure sensor is defective.
PC360LC-10 40-461
40 Troubleshooting

each female side.
required. Max. 1 z
(2) Max. 1 z
tance
required. Max. 1 z
(3)
tance
40-462 PC360LC-10
40 Troubleshooting
Circuit diagram related to bucket CURL PPC pressure sensor
PC360LC-10 40-463
40 Troubleshooting
Failure code [DHS8MA] Boom RAISE PPC Press Sensor

Abnormality (PC300-DHS8MA-400-A-Z0-A)
Action level Failure code Boom RAISE PPC Pressure Sensor Abnormality
Failure
Detail of • Signal voltage of boom RAISE PPC pressure sensor circuit is below 0.3 V or above 4.5 V.
failure
Action of • Controls machine taking it that boom RAISE PPC pressure is 0 MPa {0 kg/cm 2 }.
machine • Controllability of boom RAISE deteriorates.
• Boom RAISE PPC pressure can be checked with monitoring function.
(Code: 07400 Boom RAISE PPC pressure)
first.
Power 4.5 to 5.5
supply V
2. Insert T-adapters in connector P06.
Sensor 0.5 to 4.5
output V
Defective boom RAISE PPC sensor, ground fault or hot short circuit in wiring harness. Check as
defect)
sensor.
4. If E mark is not displayed again for this failure code, boom RAISE
40-464 PC360LC-10
40 Troubleshooting

each female side.
required. Max. 1 z
(2) Max. 1 z
tance
required. Max. 1 z
(3)
tance
PC360LC-10 40-465
40 Troubleshooting
Circuit diagram related to boom RAISE PPC pressure sensor
40-466 PC360LC-10
40 Troubleshooting
Failure code [DHS9MA] Boom LOWER Press Sensor Abnormality (PC400-

DHS9MA-400-A-Z0-A)
Action level Failure code Boom LOWER pressure sensor abnormality

Failure
Detail of • Signal voltage of boom LOWER pressure sensor circuit is below 0.3 V or above 4.5 V.
failure
controller
machine • Controllability of boom LOWER deteriorates.
• Boom lower PPC pressure can be checked with monitoring function.
(Code: 07500 Boom LOWER PPC pressure)
first.
Defective 5 V sensor power 2. Disconnect connector P02 and connect T-adapters to female side.
1 supply 2 line 3. Turn starting switch to ON position.
Power 4.5 to 5.5
supply V
Sensor 0.5 to 4.5
output V
Defective boom LOWER PPC sensor, ground fault or hot short circuit in wiring harness. Check as
defect)
sensor.
4. If E mark is not displayed again for this failure code, boom LOWER
PC360LC-10 40-467
40 Troubleshooting

each female side.
required. Max. 1 z
(2) Max. 1 z
tance
required. Max. 1 z
(3)
Resis- Between ground and CP01 (female) (13) and
ground, or between P02 (female) (2) Min. 1 Mz
tance
40-468 PC360LC-10
40 Troubleshooting
Circuit diagram related to boom LOWER PPC pressure sensor
PC360LC-10 40-469
40 Troubleshooting
Failure code [DHSAMA] Swing RH PPC Press Sensor Abnomality (PC400-

DHSAMA-400-A-Z0-A)
Action level Failure code Swing RH PPC Pressure Sensor Abnomality

Failure
L01 DHSAMA (Pump controller system)
Detail of • Signal voltage of swing RIGHT PPC pressure sensor is below 0.3 V or above 4.5 V.
failure
Action of • Controls machine taking it that swing RIGHT PPC pressure is 0 MPa {0 kg/cm 2 }.
machine • Controllability of swing RIGHT deteriorates.
• Swing RIGHT PPC pressure can be checked with monitoring function.
(Code: 09002 Swing RIGHT PPC Pressure)
first.
Power 4.5 to 5.5
supply V
2. Connect T-adapters to connector P07.
Sensor 0.5 to 4.5
output V
Defective swing right PPC sensor, ground fault or hot short circuit in wiring harness. Check as
2 pressure sensor below.
(internal defect) 1. Turn starting switch to OFF position.
sensor.
4. If E mark is not displayed again in this failure code column, swing
RIGHT PPC pressure sensor is defective.
40-470 PC360LC-10
40 Troubleshooting

each female side.
required. Max. 1 z
(2) Max. 1 z
tance
required. Max. 1 z
(3)
tance
PC360LC-10 40-471
40 Troubleshooting
Circuit diagram related to swing RIGHT PPC pressure sensor
40-472 PC360LC-10
40 Troubleshooting
Failure code [DHSBMA] Swing LH PPC Press Sensor Abnomality (PC400-

DHSBMA-400-A-Z0-A)
Action level Failure code Swing LH PPC Pressure Sensor Abnomality

Failure
L01 DHSBMA (Pump controller system)
Detail of • Signal voltage of swing LEFT PPC pressure sensor is below 0.3 V or above 4.5 V.
failure
Action of • Controls machine taking it that swing LEFT PPC pressure is 0 MPa {0 kg/cm 2 }.
machine • Controllability of swing LEFT deteriorates.
• Swing LEFT PPC pressure can be checked with monitoring function.
(Code 09001: Swing LEFT PPC pressure)
first.
Power 4.5 to 5.5
supply V
Sensor 0.5 to 4.5
output V
Defective swing left PPC sensor, ground fault or hot short circuit in wiring harness. Check as
2 pressure sensor below.
sensor.
4. If E mark is not displayed again in this failure code column, swing
LEFT PPC pressure sensor is defective.
PC360LC-10 40-473
40 Troubleshooting

each female side.
required. Max. 1 z
(2) Max. 1 z
tance
required. Max. 1 z
(3)
tance
40-474 PC360LC-10
40 Troubleshooting
Circuit diagram related to swing LEFT PPC pressure sensor
PC360LC-10 40-475
40 Troubleshooting
Failure code [DHSCMA] Arm OUT PPC Press Sensor Abnormality (PC400-
DHSCMA-400-A-Z0-A)
Action level Failure code Arm OUT PPC Pressure Sensor Abnormality
Failure
L01 DHSCMA (Pump controller system)
Detail of • Signal voltage of arm OUT PPC pressure sensor is below 0.3 V or above 4.5 V.
failure
Problem on • Machine monitor does not display working radius, actual load and lifting height.
machine
Related be measured at pump controller connector.
information • Arm OUT PPC pressure can be checked with monitoring function.
(Code: 07600 Arm OUT PPC pressure)
• Method of reproducing failure code: Turn starting switch to ON position or start engine,
and select arm crane mode (L).

first.
Defective 5 V sensor power 2. Disconnect connector P08, and connect T-adapters to female side.
1 supply 2 line 3. Turn starting switch to ON position.
Power 4.5 to 5.5
supply V
Sensor 0.5 to 4.5
output V
Defective arm OUT PPC sensor, ground fault or hot short circuit in wiring harness. Check as
failure)
sensor.
4. If E mark is not displayed again in this failure code column, arm OUT
40-476 PC360LC-10
40 Troubleshooting

each female side.
required. Max. 1 z
(2) Max. 1 z
tance
required. Max. 1 z
(3)
tance
PC360LC-10 40-477
40 Troubleshooting
Circuit diagram related to arm OUT PPC pressure sensor
40-478 PC360LC-10
40 Troubleshooting
Failure code [DHSDMA] Bucket Dump PPC Press Sensor

Abnormality (PC400-DHSDMA-400-A-Z0-A)
Action level Failure code Bucket Dump PPC Pressure Sensor Abnormality
Failure
L01 DHSDMA (Pump controller system)
Detail of • Signal voltage of bucket DUMP PPC pressure sensor is below 0.3 V or above 4.5 V.
failure
Action of • Controls machine taking it that bucket DUMP PPC pressure is 0 MPa {0 kg/cm 2 }.
machine • Controllability of bucket DUMP deteriorates.
• Bucket DUMP PPC pressure can be checked with monitoring function.
(Code: 07301 Bucket DUMP PPC pressure)

first.
Power 4.5 to 5.5
supply V
Sensor 0.5 to 4.5
output V
Defective bucket DUMP PPC sensor, ground fault or hot short circuit in wiring harness. Check as
defect)
sensor.
4. If E mark is not displayed again in this failure code column, bucket
DUMP PPC pressure sensor is defective.
PC360LC-10 40-479
40 Troubleshooting

each female side.
required. Max. 1 z
(2) Max. 1 z
tance
required. Max. 1 z
(3)
tance
40-480 PC360LC-10
40 Troubleshooting
Circuit diagram related to bucket DUMP PPC pressure sensor
PC360LC-10 40-481
40 Troubleshooting
Failure code [DHSFMA] Travel FW L PPC Press Sensor Abnormality (PC400-

DHSFMA-400-A-Z0-A)
PC490LC-10
Action level Failure code Travel Forward Left PPC Pressure Sensor Abnormality
Failure
L01 DHSFMA (Pump controller system)
Detail of • Signal voltage of left travel FORWARD PPC pressure sensor is below 0.3 V or above 4.5
failure V.
Action of • Controls machine taking it that left travel FORWARD PPC pressure is 0 MPa {0 kg/cm 2 }.
machine • Controllability of travel deteriorates.
• Left travel FORWARD PPC pressure can be checked with monitoring function.
(Code: 07102 Travel Fwd LH PPC pressure)
first.
Power 4.5 to 5.5
supply V
2. Insert T-adapter into connector P09.
Sensor 0.5 to 4.5
output V
Defective left travel sensor, ground fault or hot short circuit in wiring harness. Check as
2 FORWARD PPC pressure below.
sensor (internal defect)
sensor.
4. If E mark is not displayed in this failure code column, travel
FORWARD LH PPC pressure sensor is defective.
40-482 PC360LC-10
40 Troubleshooting

each female side.
required. Max. 1 z
(2) Max. 1 z
tance
required. Max. 1 z
(3)
tance
PC360LC-10 40-483
40 Troubleshooting
Circuit diagram related to travel PPC pressure sensor
40-484 PC360LC-10
40 Troubleshooting
Failure code [DHSGMA] Travel FW R PPC Press Sensor

Abnormality (PC400-DHSGMA-400-A-Z0-A)
Action level Failure code Travel Forward Right PPC Pressure Sensor Abnormality
Failure
L01 DHSGMA (Pump controller system)
Detail of • Signal voltage of right travel FORWARD PPC pressure sensor is below 0.3 V or above
failure 4.5 V.
• Controls machine taking it that right travel FORWARD PPC pressure is 0 MPa {0 kg/cm 2
Action of }.
• Right travel FORWARD PPC pressure can be checked with monitoring function.
(Code: 07103 Travel Fwd RH PPC pressure)
first.
Power 4.5 to 5.5
supply V
2. Insert T-adapter into connector P11.
Sensor 0.5 to 4.5
output V
Defective right travel abnormal, it is difficult to judge whether cause of failure is defective
FORWARD PPC pressure sensor, ground fault or hot short circuit in wiring harness. Check as
2 sensor below.
sensor.
FORWARD RH PPC pressure sensor is defective.
PC360LC-10 40-485
40 Troubleshooting

each female side.
required. Max. 1 z
(2) Max. 1 z
tance
required. Max. 1 z
(3)
Resis- Between ground and CP01 (female) (72) or P11
tance
(Contact with 5 V/24 V circuit) 4. Turn starting switch to ON position.
40-486 PC360LC-10
40 Troubleshooting
PC360LC-10 40-487
40 Troubleshooting
Failure code [DHSHMA] Travel BW L PPC Press Sensor

Abnormality (PC400-DHSHMA-400-A-Z0-A)
Action level Failure code Travel Backward Left PPC Pressure Sensor Abnormality
Failure
L01 DHSHMA (Pump controller system)
Detail of • Signal voltage of left travel REVERSE PPC pressure sensor is below 0.3 V or above 4.5
failure V.
Action of • Controls machine taking it that left travel REVERSE PPC pressure is 0 MPa {0 kg/cm 2 }.
• Left travel REVERSE PPC pressure can be checked with monitoring function.
(Code: 07104 Travel Rev LH PPC Pressure)

first.
Power 4.5 to 5.5
supply V
Sensor 0.5 to 4.5
output V
Defective left travel abnormal, it is difficult to judge whether cause of failure is defective
REVERSE PPC pressure sensor, ground fault or hot short circuit in wiring harness. Check as
2 sensor below.
sensor.
REVERSE LH PPC pressure sensor is defective.
40-488 PC360LC-10
40 Troubleshooting

each female side.
required. Max. 1 z
(2) Max. 1 z
tance
required. Max. 1 z
(3)
tance
PC360LC-10 40-489
40 Troubleshooting
40-490 PC360LC-10
40 Troubleshooting
Failure code [DHSJMA] Travel BW R PPC Press Sensor

Abnormality (PC400-DHSJMA-400-A-Z0-A)
Action level Failure code Travel Backward Right PPC Pressure Sensor Abnormality
Failure
L01 DHSJMA (Pump controller system)
Detail of • Signal voltage of right travel REVERSE PPC pressure sensor is below 0.3 V or above 4.5
failure V.
Action of • Controls machine taking it that right travel REVERSE PPC pressure is 0 MPa {0 kg/cm 2 }.
machine • Controllability of right travel REVERSE deteriorates.
• Right travel REVERSE PPC pressure can be checked with monitoring function.
(Code: 07105 Travel Rev RH PPC pressure)
first.
Power 4.5 to 5.5
supply V
Sensor 0.5 to 4.5
output V
Defective right travel abnormal, it is difficult to judge whether cause of failure is defective
REVERSE PPC pressure sensor, ground fault or hot short circuit in wiring harness. Check as
2 sensor below.
sensor.
REVERSE RH PPC pressure sensor is defective.
PC360LC-10 40-491
40 Troubleshooting

each female side.
required. Max. 1 z
(2) Max. 1 z
tance
required. Max. 1 z
(3)
tance
40-492 PC360LC-10
40 Troubleshooting
PC360LC-10 40-493
40 Troubleshooting
Failure code [DKR0MA] F pump S/P sensor Abnormality (PC400-DKR0MA-400-A-Z0-A)
Action level Failure code Front pump Swash Plate Sensor Abnormality
Failure
L01 DKR0MA (Pump controller system)
Detail of • Signal voltage of F pump swash plate sensor circuit is below 0.4 V or above 4.6 V.
failure

controller
• Automatic deceleration does not cancel.
Problem on • One-touch power maximizing function does not work.
machine • When engine is running with light load, engine control that runs engine at lowered engine-
pump matching speed does not function.
a If 5 V circuit (A) and ground circuit (B) of swash plate sensor are connected inversely,
sensor will be broken. Accordingly, take extreme care when checking.
• Voltage from front pump swash plate sensor can be checked with monitoring function.
(Code: 01138 F pump swash plate sensor voltage)
first.
Power 4.5 to 5.5
Voltage Between P27 (female) (A) and (B)
supply V
Between P27 (male) (A) and (B) Approx. 6
kz
Approx. 6
Resis- Between P27 (female) (B) and (C) kz
tance Approx.
Between P27 (female) (A) and (C)
170 z
Between P27 (male) (C) and ground Min. 1 Mz
Defective F pump swash 3. Turn starting switch to ON position.
2 plate sensor Sensor Approx. 3
Voltage Between P27 (C) and (B)
(internal defect) output V
sensor, ground fault or hot short circuit in wiring harness. Check as
below.
2. Replace connector P27 with connector P28.
4. If E mark is not displayed again in this failure code column, F pump
swash plate sensor is defective.
a After finishing test, restore connectors .
40-494 PC360LC-10
40 Troubleshooting

each female side.
required. Max. 1 z
3 (wire breakage or defective (A)
tance
required. Max. 1 z
(B)
(C) Max. 1 z

P27 (female) (C) Min. 1 Mz
tance
Voltage Between P27 (female) (C) and ground Max. 1 V
Circuit diagram related to F and R pump swash plate sensors
PC360LC-10 40-495
40 Troubleshooting
Failure code [DKR1MA] R pump S/P sensor Abnormality (PC400-DKR1MA-400-A-Z0-A)
Action level Failure code Rear Pump Swash Plate Sensor Abnormality
Failure
L01 DKR1MA (Pump controller system)
Detail of • Signal voltage of R pump swash plate sensor circuit is below 0.4 V or above 4.6 V.
failure
controller
• Automatic deceleration does not cancel.
Problem on • One-touch power maximizing function does not work.
machine • When engine is running with light load, engine control that runs engine at lowered engine-
pump matching speed does not function.
a If 5 V circuit (A) and ground circuit (B) of swash plate sensor are connected inversely,
sensor will be broken. Accordingly, take extreme care when checking.
• Voltage from rear pump swash plate sensor can be checked with monitoring function.
(Code: 01140 R Pump Sw Plate Sensor Volt)
first.
Power 4.5 to 5.5
Voltage Between P28 (female) (A) and (B)
supply V
Between P28 (male) (A) and (B) Approx. 6
kz
Approx. 6
Resis- Between P28 (female) (B) and (C) kz
tance Approx.
Between P28 (female) (A) and (C)
170 z
Between P28 (male) (C) and ground Min. 1 Mz
2. Insert T-adapters into connector P28
Defective R pump swash 3. Turn starting switch to ON position.
2 plate sensor Sensor Approx. 3
Voltage Between P28 (C) and (B)
(internal defect) output V
sensor, ground fault or hot short circuit in wiring harness. Check as
below.
2. Replace connector P28 with connector P27.
4. If E mark is not displayed again in this failure code column, R pump
swash plate sensor is defective.
3 (wire breakage or defective 2. Disconnect connectors CP01 and P28, and connect T-adapters to
40-496 PC360LC-10
40 Troubleshooting

required. Max. 1 z
(A)
Resis-
tance
required. Max. 1 z
(B)
(C) Max. 1 z

P28 (female) (C) Min. 1 Mz
tance
(contact with 24 v circuit) 4. Turn starting switch to ON position.
Voltage Between P28 (female) (C) and ground Max. 1 V
Circuit diagram related to F and R pump swash plate sensors
PC360LC-10 40-497
40 Troubleshooting
Failure code [DR21KX] Camera 2 Picture Rev. Drive Abnormality (PC400-

DR21KX-400-A-Z0-A)
Action level Failure code Camera 2 Picture Reverse Drive Abnormality

Failure
L01 DR21KX (Machine monitor system)
Detail of • Voltage that is different from output voltage of machine monitor appears in camera 2
failure picture reverse drive circuit (pin 6 of connector CM04).
Action of • Does not display camera 2 image.
controller
Problem on • Camera 2 image is not displayed.
machine
• Normal image is displayed when voltage of camera 2 picture reverse drive circuit (pin 6 of
connector CM04) is 0V, and mirror image is displayed when voltage is 8 V (mirror image
Related command of 8 V is used because camera power supply voltage is 8 V).
information • Since there may be several connectors A46, check connector A41 to identify the camera
2.
2. Disconnect connectors CM04 and A46, and connect T-adapters to
1 (Wire breakage or defective Between CM04 (female) (6) and A46 (female)
Max. 1 z
contact of connector) Resis- (3)
tance Between CM04 (female) (8) and A46 (female)
(4) Max. 1 z

Ground fault in wiring harness 2. Disconnect connectors CM04 and A46, and connect T-adapter to
(Contact with ground circuit)
Resis- Between ground and CM04 (female) (6) or A46
tance
Hot short circuit in wiring 2. Disconnect connector A46 and connect T-adapter to female side.
(Contact with 24 V circuit) a Check that normal image setting is selected for camera 2.
Voltage Between A46 (female) (3) and (4) or ground Max. 1 V
2. Disconnect connector CM04 and connect T-adapter to female side.
Resis- Between CM04 (female) (6) and every pin
other than pin (6) Min. 1 Mz
tance
If no failure is found by above checks, camera 2 is defective. (Since this
5 Defective camera 2 is an internal defect, troubleshooting cannot be performed.)
If no failure is found in above checks, machine monitor is defective.
40-498 PC360LC-10
40 Troubleshooting
Circuit diagram related to camera
PC360LC-10 40-499
40 Troubleshooting
Failure code [DR31KX] Camera 3 Picture Rev. Drive Abnormality (PC400-

DR31KX-400-A-Z0-A)
Action level Failure code Camera 3 Picture Reverse Drive Abnormality

Failure
L01 DR31KX (Machine monitor system)
Detail of • Voltage that is different from output voltage of machine monitor is detected in camera 3
failure picture reverse drive circuit (pin 7 of connector CM04).
Action of • Does not display camera 3 image.
controller
Problem on • Camera 3 image is not displayed.
machine
• Normal image is displayed when voltage of camera 3 picture reverse drive circuit (pin 7 of
connector CM04) is 0 V, and mirror image is displayed when voltage is 8 V (mirror image
Related command of 8 V is used because camera power supply voltage is 8 V).
information • Since there may be several connectors A46, check connector A42 to identify the camera
3.
2. Disconnect connectors CM04 and A46, and connect T-adapters to
1 (Wire breakage or defective Between CM04 (female) (7) and A46 (female)
Max. 1 z
contact of connector) Resis- (3)
tance Between CM04 (female) (8) and A46 (female)
(4) Max. 1 z

Ground fault in wiring harness 2. Disconnect connectors CM04 and A46, and connect T-adapter to
(Contact with ground circuit)
Resis- Between ground and CM04 (female) (7) or A46
tance
Hot short circuit in wiring 2. Disconnect connector A46 and connect T-adapter to female side.
(Contact with 24 V circuit) a Check that normal image setting is selected for camera 3.
Voltage Between A46 (female) (3) and (4) or ground Max. 1 V
2. Disconnect connector CM04 and connect T-adapter to female side.
Resis- Between CM04 (female) (7) and every pin
other than pin (7) Min. 1 Mz
tance
If no failure is found by above checks, camera 3 is defective. (Since this
5 Defective camera 3 is an internal defect, troubleshooting cannot be performed.)
If no failure is found in above checks, machine monitor is defective.
40-500 PC360LC-10
40 Troubleshooting
Circuit diagram related to camera
PC360LC-10 40-501
40 Troubleshooting
Failure code [DV20KB] Travel Alarm Short Circuit (PC400-DV20KB-400-A-Z0-A)
Action level Failure code Travel Alarm Short Circuit

Failure
L01 DV20KB (Pump controller system)
Detail of • Abnormal current flows when pump controller drives travel alarm circuit.
failure
• Stops driving travel alarm circuit.
controller is set to OFF position.
Problem on
• Travel alarm does not sound.
machine
2. Disconnect connector M14, and connect T-adapter to female side.
4. Perform troubleshooting by operating the travel lever.
k Never enter under the machine when operating travel lever.
Defective travel alarm
1 a When travel lever is set to the travel position, voltage is applied usually to
(Internal defect)
the travel alarm connector before machine starts moving.
a If the following voltage is normal but travel alarm does not sound, travel
alarm is defective.
Travel lever: Neutral Max. 1 V
Between M14 (female)
Voltage Travel lever: When
(1) and (2) 20 to 30 V
operated
harness 2. Disconnect connectors CP02 and M14, and connect T-adapter to either
2 female side.
Between CP02 (female) (107) and ground, or M14
circuit) Resistance (female) (1) and ground Min. 1 Mz

2. Insert T-adapter into connector M14.
4. Perform troubleshooting by operating the travel lever.
Pump controller is
3
defective. k Never enter under the machine when operating travel lever.
Travel lever: Neutral Max. 1 V
Voltage Between M14 (1) and (2) Travel lever: When
operated 20 to 30 V
40-502 PC360LC-10
40 Troubleshooting
Circuit diagram related to travel alarm
PC360LC-10 40-503
40 Troubleshooting
Failure code [DW43KA] Travel Speed Sol Open Circuit (PC300-DW43KA-400-A-Z0-A)
Action level Failure code Travel Speed Solenoid Open Circuit

Failure
L01 DW43KA (Pump controller system)
Detail of • No current flows when pump controller drives travel speed selector solenoid, so pump
failure controller determines that open circuit exists in travel speed selector solenoid circuit.
Action of • None in particular (Since no current flows, solenoid is not energized.)
Problem on • "Hi" travel speed is slow. (Although "Hi" is diaplayed on machine monitor, actual travel
machine speed is still "Lo".)
• Controller's command (ON/OFF) to travel speed selector solenoid can be checked with
monitoring function. (As long as controller's command to solenoid is "ON", sensor status
displayed on monitoring screen is "ON" even if solenoid is not energized due to short
Related
circuit.)
information
(Code: 02300 Solenoid 1)
• Method of reproducing failure code: Start engine, set travel speed to High and operate
travel lever.
Defective travel speed 1. Turn starting switch to OFF position.
1 selector solenoid 2. Disconnect connector V04, and connect T-adapters to male side.
(Internal open circuit) Resistance Between V04 (male) (1) and (2) 20 to 60 z
Between CP02 (female) (93) and each of
Resistance (115), (117), and (120) 20 to 60 z
a If no failure is found by above checks , this check is not required.
harness
2 1. Turn starting switch to OFF position.
2. Disconnect connectors CP02 and V04, and connect T-adapters to
each female side.
Between CP02 (female) (93) and V04
Resistance
Between V04 (female) (2) and each of CP02
(female) (115), (117), and (120) Max. 1 z
40-504 PC360LC-10
40 Troubleshooting
Circuit diagram related to travel speed selector solenoid
PC360LC-10 40-505
40 Troubleshooting
Failure code [DW43KB] Travel Speed Sol Short Circuit (PC300-DW43KB-400-A-Z0-A)
Action level Failure code Travel Speed Solenoid Short Circuit

Failure
L01 DW43KB (Pump controller system)
• Abnormal current flows when pump controller drives travel speed selector solenoid, so
Detail of
pump controller determines that short circuit exists in travel speed selector solenoid
failure
circuit.
• Stops driving travel speed selector solenoid.
Problem on • "Hi" travel speed is slow. (Although "Hi" is diaplayed on machine monitor, actual travel
machine speed is still "Lo".)
• Controller's command (ON/OFF) to travel speed selector solenoid can be checked with
Related
circuit.)
information
• Method of reproducing failure code: Start engine, set travel speed to High and operate
travel lever.
selector solenoid 2. Disconnect connector V04, and connect T-adapters to male side.
1
(internal short circuit or Between V04 (male) (1) and (2) 20 to 60 z
ground fault) Resistance
Between V04 (male) (1) and ground Min. 1 Mz
Short circuit or ground fault in
2 wiring harness Between CP02 (female) (93) and (115),
20 to 60 z
Resistance (117), (120)
Between CP02 (female) (93) and ground Min. 1 Mz
a If no abnormality is found in check on cause 2, this check is not
required.
3 harness
2. Disconnect connectors C02 and V04, and connect T-adapter to either
(contact with ground circuit) female side.
Between ground and CP02 (female) (93) or
Resistance between V04 (female) (1) Min. 1 Mz
40-506 PC360LC-10
40 Troubleshooting
PC360LC-10 40-507
40 Troubleshooting
Failure code [DW45KA] swing holding brake Sol Open Circuit (PC300-DW45KA-400-
A-Z0-A)
Action level Failure code Swing Holding Brake Solenoid Open Circuit
Failure
• Controller output voltage to solenoid is above standard value when pump controller does
Detail of not drive swing holding brake solenoid, so pump controller determines that open circuit
failure exists in swing holding brake solenoid circuit.
• None in particular. (Since no current flows, solenoid is not energized, so swing holding
Action of brake is kept applied.)
Problem on • Upper structure does not swing (swing holding brake is not released).
machine
• When solenoid and wiring harness are normal, swing operation is possible if swing brake
cancel switch is set to RELEASE position. (Note that swing holding brake is applied when
starting switch is in OFF position.)
• Keep swing brake cancel switch in RELEASE position during troubleshooting. When
starting switch is turned to ON position in this condition, normally current flows through
swing holding brake solenoid circuit to release swing holding brake.
Related • Controller's command (ON/OFF) to swing holding brake solenoid can be checked with
information monitoring function. (As long as controller's command to solenoid is "ON", sensor status
displayed on monitoring screen is "ON" even if solenoid is not energized due to open
circuit.)
• Power for swing holding brake solenoid circuit is supplied from pin (101) of pump
controller connector CP02 or fuse No.1 in fuse box F01.
Blown fuse No. 1 (right top
1 If fuse is blown, see failure code [DW45KB].
fuse) in fuse box F01
Defective swing holding 2. Disconnect connector V05, and connect T-adapters to male side.
2
brake solenoid
Resistance Between V05 (male) (1) and (2) 20 to 60 z
2. Remove diode arrays D01 and D03, and connect T-adapters to each
male side.
Defective diode array D01 or a Check by using multimeter in diode range.
3
D03 Between D01 (male) (3) (+) and (7) (-) No continuity
Continuity
40-508 PC360LC-10
40 Troubleshooting

2. Remove diode D01.
3. Disconnect connector CP02, and connect T-adapter to each female
side.
a Swing lock switch OFF position.
Between CP02 (female) (101) and D01
Open circuit in wiring Resistance
harness Between D01 (female) (3) and CP02
(female) (115) 20 to 60 z
4
contact of connector) a If no failure is found by above checks, this check is not required.
2. Disconnect connectors D01, CP02, and V05, and connect T-adapters
Between D01 (female) (3) and V05 (female)
(1) Max. 1 z
Resistance
Between each of CP02 (female) (115),
(117), (120), and V05 (female) (2) Max. 1 z
PC360LC-10 40-509
40 Troubleshooting
Circuit diagram related to swing holding brake solenoid
40-510 PC360LC-10
40 Troubleshooting
Failure code [DW45KB] Swing Brake Sol Short Circuit (PC300-DW45KB-400-A-Z0-A)
Action level Failure code Swing Brake Solenoid Short Circuit

Failure
Detail of • Abnormal current flows when pump controller drives swing holding brake solenoid, so
failure pump controller determines that short circuit exists in swing holding brake solenoid circuit.
• Stops driving swing holding brake solenoid.
Problem on • Upper structure does not swing (swing holding brake is not released).
machine
• When solenoid and wiring harness are normal, swing operation is possible if swing brake
cancel switch is set to RELEASE position. (Note that swing holding brake is applied when
starting switch is in OFF position.)
• Keep swing lock switch in OFF position and swing brake cancel switch in RELEASE
position during troubleshooting. When starting switch is turned to ON position in this
condition, normally current flows through swing holding brake solenoid circuit to release
swing holding brake.
Related
• Controller's command (ON/OFF) to swing holding brake solenoid can be checked with
information
circuit.)
• Power for swing holding brake solenoid circuit is supplied from pin (101) of pump
controller connector CP02 or fuse No.1 in fuse box F01.
Blown fuse No. 1 (right top Even if fuse is blown, perform troubleshooting according to following
1 fuse) in fuse box F01 steps to identify cause.
Defective swing holding 2. Disconnect connector V05, and connect T-adapters to male side.
2
brake solenoid Resis- Between V05 (male) (1) and (2) 20 to 60 z
tance Between V05 (male) (1) and ground Min. 1 Mz
2. Remove diode arrays D01 and D03, and connect T-adapters to each
male side.
a Check by using multimeter in diode range.
Defective diode array D01 or No
3 Between D01 (male) (3) (+) and (7) (-)
D03 continuity
Continuity
No
Between D03 (male) (1) (+) and (5) (-)
continuity
2. Remove fuse No.1 (right top, 10 A) in fuse box F01 and diode D01.
Ground fault in wiring harness 3. Disconnect connectors CP02, D01, and V05.
4 4. Connect T-adapters to female side of connectors CP02 and D01.
Resis- Between CP02 (female) (101) and ground Min. 1 Mz
tance Between D01 (female) (3) and ground Min. 1 Mz
PC360LC-10 40-511
40 Troubleshooting

2. Remove fuse No.1 (right top, 5 A) in fuse box F01 and diode D01.
3. Disconnect connector CP02.
4. Connect T-adapters to female side of connectors D01 and CP02.
Resis- Between D01 (female) (3) and CP02 (female)
(115), (117), or (120) 20 to 60 z
tance
40-512 PC360LC-10
40 Troubleshooting
PC360LC-10 40-513
40 Troubleshooting
Failure code [DW91KA] Travel Junction Sol Open Circuit (PC300-DW91KA-400-A-Z0-A)
Action level Failure code Travel Junction Solenoid Open Circuit

Failure
Detail of not drive travel junction solenoid, so pump controller determines that open circuit exists in
failure travel junction solenoid circuit.
Problem on • Machine does not turn during travel.
machine
• Controller's command (ON/OFF) to travel junction solenoid can be checked with
Related circuit.)
information (Code: 02300 Solenoid 1)
• Travel junction circuit is made when solenoid is de-energized.
• Method of reproducing failure code: Start engine and turn machine with right and left
travel levers.
Defective travel junction 1. Turn starting switch to OFF position.
solenoid 2. Disconnect connector V03, and connect T-adapters to male side.
1
(Internal open circuit) Resis- Between V03 (male) (1) and (2)
20 to 60 z
tance
Open or short circuit in wiring 2. Disconnect connector CP02 and connect T-adapters to female side.
2
harness Resis- Between CP02 (female) (85) and each of (115),
(117), (120) 20 to 60 z
tance
Open circuit in wiring harness 2. Disconnect connectors CP02 and V03, and connect T-adapters to
contact of connector) Between CP02 (female) (85) and V03 (female)
Max. 1 z
Resis- (1)
tance Between each of CP02 (female) (115), (117),
(120) and V03 (female) (2) Max. 1 z
40-514 PC360LC-10
40 Troubleshooting
Circuit diagram related to travel junction solenoid
PC360LC-10 40-515
40 Troubleshooting
Failure code [DW91KB] Travel Junction Sol Short Circuit (PC300-DW91KB-400-A-Z0-A)
Action level Failure code Travel Junction Solenoid Short Circuit

Failure
Detail of • Abnormal current flows when pump controller drives travel junction solenoid, so pump
failure controller determines that short circuit exists in travel junction solenoid circuit.
• Stops driving travel junction solenoid.
Problem on • Machine does not turn during travel.
machine
• Controller's command (ON/OFF) to travel junction solenoid can be checked with
Related circuit.)
• Travel junction circuit is made when solenoid is de-energized.
• Method of reproducing failure code: Start engine and turn machine with right and left
travel levers.
Defective travel junction 1. Turn starting switch to OFF position.
1
(internal short circuit or Resis- Between V03 (male) (1) and (2) 20 to 60 z
ground fault) tance Between V03 (male) (1) and ground Min. 1 Mz
2 wiring harness Between CP02 (female) (85) and each of (115),
Resis- (117), (120) 20 to 60 z
tance
3 2. Disconnect connectors CP02 and V03, and connect T-adapters to
V03 (female) (1) Min. 1 Mz
tance
40-516 PC360LC-10
40 Troubleshooting
Circuit diagram related to travel junction solenoid
PC360LC-10 40-517
40 Troubleshooting
Failure code [DWA2KA] Attachment Sol Open Circuit (PC300-DWA2KA-400-A-Z0-A)
Action level Failure code Attachment solenoid Open Circuit

Failure
L03 DWA2KA (Pump controller system)
Detail of not drive attachment return (1-way/2-way selector) solenoid, so pump controller
failure determines that open circuit exists in travel junction solenoid circuit.
Problem on • Attachment return circuit does not change to 1-way circuit.
machine
• Controller's command (ON/OFF) to attachment return selector solenoid can be checked
with monitoring function. (As long as controller's command to solenoid is "ON", sensor
status displayed on monitoring screen is "ON" even if solenoid is not energized due to
Related open circuit.)
• Method of reproducing failure code: Turn starting switch to ON position and set machine in
working mode other than breaker mode (B).
Defective attachment return 1. Turn starting switch to OFF position.
1 selector solenoid (internal 2. Disconnect connector V07, and connect T-adapters to male side.
open circuit) Resistance Between V07 (male) (1) and (2) 20 to 60 z
Open circuit or ground fault 2. Disconnect connector CP02 and connect T-adapters to female side.
2 in wiring harness Between CP02 (female) (86) and each of
Resistance CP02 (female) (115), (117), (120) 20 to 60 z

Open circuit in wiring 2. Disconnect connectors CP02 and V07, and connect T-adapters to
3
(wire breakage or defective Between CP02 (female) (86) and V07
contact of connector) (female) (1) Max. 1 z
Resistance
(117), (120) and V07 (female) (2) Max. 1 z
40-518 PC360LC-10
40 Troubleshooting
Circuit diagram related to attachment return (1-way/2-way) selector solenoid
PC360LC-10 40-519
40 Troubleshooting
Failure code [DWA2KB] Attachment Sol Short Circuit (PC300-DWA2KB-400-A-Z0-A)
Action level Failure code Attachment Solenoid Short Circuit

Failure
L03 DWA2KB (Pump controller system)
• Abnormal current flows when pump controller drives attachment return selector solenoid,
Detail of
so pump controller determines that short circuit exists in attachment return selector
failure
solenoid circuit.
• Stops driving attachment return selector solenoid.
Problem on • Attachment return circuit does not change to 1-way circuit.
machine
• Controller's command (ON/OFF) to attachment return selector solenoid can be checked
with monitoring function. (As long as controller's command to solenoid is "ON", sensor
status displayed on monitoring screen is "ON" even if solenoid is not energized due to
Related short circuit.)
• Method of reproducing failure code: Turn starting switch to ON position and set machine in
breaker mode (B).
Defective attachment return 2. Disconnect connector V07, and connect T-adapters to male side.
1 selector solenoid (internal
short circuit or ground fault) Between V07 (male) (1) and (2) 20 to 60 z
Resistance
Resistance (115), (117), (120) 20 to 60 z

3 harness 2. Disconnect connectors CP02 and V07, and connect T-adapters to
Resistance V07 (female) (1) Min. 1 Mz
40-520 PC360LC-10
40 Troubleshooting
Circuit diagram related to attachment return (1-way/2-way) selector solenoid
PC360LC-10 40-521
40 Troubleshooting
Failure code [DWK0KA] 2-stage Relief Sol Open Circuit (PC300-DWK0KA-400-A-Z0-A)
Action
Failure code 2-stage Relief Solenoid Open Circuit
level Failure
(Pump controller system)
L01 DWK0KA
Detail of not drive 2-stage relief solenoid, so pump controller determines that open circuit exists in
failure 2-stage relief solenoid circuit.
Problem on • Travel power is low (main relief valve is not set to high-pressure setting).
machine • One-touch power maximizing function does not operate
• Controller's command (ON/OFF) to 2-stage relief solenoid can be checked with
circuit.)
Related (Code: 02300 Solenoid 1)
information • As T-adapter for pump controller connector is "socket-type box", operating voltage cannot
• Controller detects open circuit only when it does not drive solenoid.
Defective 2-stage relief 1. Turn starting switch to OFF position.
1 solenoid 2. Disconnect connector V08, and connect T-adapters to male side.
Open or short circuit in wiring a If resistance is above 1 Mz , wiring harness has open circuit. If
2
harness resistance is below 1 z , wiring harness has short circuit.
Resistance (115), (117) and (120) 20 to 60 z

3
Resistance
(117), (120) and V03 (female) (2) Max. 1 z
40-522 PC360LC-10
40 Troubleshooting
Circuit diagram related to 2-stage relief solenoid
PC360LC-10 40-523
40 Troubleshooting
Failure code [DWK0KB] 2-stage Relief Sol Short Circuit (PC300-DWK0KB-400-A-Z0-A)
Action
Failure code 2-stage Relief Solenoid Short Circuit
level Failure
(Pump controller system)
L01 DWK0KB
Detail of • Abnormal current flows when pump controller drives 2-stage relief solenoid, so pump
failure controller determines that short circuit exists in 2-stage relief solenoid circuit.
• Stops driving 2-stage relief solenoid.
controller is set to OFF position.
Problem on • Travel power is low (main relief valve is not set to high-pressure setting).
machine • One-touch power maximizing function does not operate
• Controller's command (ON/OFF) to 2-stage relief solenoid can be checked with
circuit.)
Related (Code: 02300 Solenoid 1)
information • As T-adapter for pump controller connector is "socket-type box", operating voltage cannot
• Controller detects open circuit only when it does not drive solenoid.
1
ground fault) tance Between V08 (female) (1) and ground Min. 1 Mz
Ground fault in wiring harness 2. Disconnect connectors CP02 and V08, and connect T-adapters to
2 female side of V08.
tance
2. Disconnect connectors CP02 and V08, and connect T-adapters to
3 Short circuit in wiring harness female side of V08.
Resis- Between V08 (female) (1) and (2)
Min. 1 Mz
tance
40-524 PC360LC-10
40 Troubleshooting
PC360LC-10 40-525
40 Troubleshooting
Failure code [DWK2KA] Variable Back Pressure Sol Open Circuit (PC300-
DWK2KA-400-A-Z0-A)
Action level Failure code Variable Back Pressure Solenoid Open Circuit
Failure
L01 DWK2KA (Pump controller system)
Detail of • No current flows when pump controller drives variable back pressure solenoid, so pump
failure controller determines that open circuit exists in variable back pressure solenoid circuit.
Problem on • Fuel consumption increases.
machine
• Controller's command (ON/OFF) to variable back pressure solenoid can be checked with
Related circuit.)
• Back pressure valve is set to low-pressure setting when solenoid is energized.
Defective variable back 1. Turn starting switch to OFF position.
1 pressure solenoid valve 2. Disconnect connector V25, and connect T-adapter to male side.
Resistance CP02 (female) (115), (117), (120) 20 to 60 z

3
Resistance
(117), (120) and V26 (female) (2) Max. 1 z
40-526 PC360LC-10
40 Troubleshooting
Circuit diagram related to variable back pressure solenoid
PC360LC-10 40-527
40 Troubleshooting
Failure code [DWK2KB] Variable Back Pressure Sol Short Circuit (PC300-
DWK2KB-400-A-Z0-A)
Action level Failure code Variable Back Pressure Solenoid Short Circuit
Failure
L01 DWK2KB (Pump controller system)
• Abnormal current flows when pump controller drives variable back pressure solenoid, so
Detail of
pump controller determines that short circuit exists in variable back pressure solenoid
failure
circuit.
• Stops driving variable back pressure solenoid.
Problem on • Fuel consumption increases.
machine
• Controller's command (ON/OFF) to variable back pressure solenoid can be checked with
Related circuit.)
• Back pressure valve is set to low-pressure setting when solenoid is energized.
Defective variable back 1. Turn starting switch to OFF position.
pressure solenoid valve 2. Disconnect connector V25, and connect T-adapters to male side.
1
(internal short circuit or Between V25 (male) (1) and (2) 20 to 60 z
ground fault) Resistance
Resistance (115), (117), (120) 20 to 60 z

3 harness 2. Disconnect connectors CP02 and V25, and connect T-adapter to
Resistance V25 (female) (1) Min. 1 Mz
40-528 PC360LC-10
40 Troubleshooting
Circuit diagram related to variable back pressure solenoid
PC360LC-10 40-529
40 Troubleshooting
Failure code [DWK8KA] Swing C/O Solenoid Open Circuit (PC300-DWK8KA-400-A-Z0-A)
Action level Failure code Swing Cut-off Solenoid Open Circuit

Failure
L01 DWK8KA (Pump controller system)
Detail of • No current flows when pump controller drives swing cut-off solenoid, so pump controller
failure determines that open circuit exists in swing cut-off solenoid circuit.
Problem on • Swing acceleration is degraded.
machine
• Controller's command (ON/OFF) to swing cut-off solenoid can be checked by using
Related circuit.)
• Swing motor relief pressure is set to "Hi" when solenoid is energized.
• Method of reproducing failure code: Turn starting switch to ON position and perform
hydraulic relief of swing system (with swing lock switch at OFF).
Defective swing cut-off 1. Turn starting switch to OFF position.

solenoid (internal open 2. Disconnect connector V02, and connect T-adapters to male side.
1
circuit) Resis- Between V02 (male) (1) and (2)
20 to 60 z
tance
Open circuit or ground fault in 2. Disconnect connector CP02 and connect T-adapters to female side.
2 wiring harness Resis- Between CP02 (female) (94) and each of CP02
(female) (115), (117), (120) 20 to 60 z
tance
Max. 1 z
Resis- (1)
and (120), and V02 (female) (2) Max. 1 z
40-530 PC360LC-10
40 Troubleshooting
Circuit diagram related to swing cut-off solenoid
PC360LC-10 40-531
40 Troubleshooting
Failure code [DWK8KB] Swing C/O Solenoid Short Circuit (PC300-DWK8KB-400-A-Z0-A)
Action level Failure code Swing Cut-off Solenoid Short Circuit

Failure
L01 DWK8KB (Pump controller system)
Detail of • Abnormal current flows when pump controller drives swing cut-off solenoid, so pump
failure controller determines that short circuit exists in swing cut-off solenoid circuit.
• Swing cut-off solenoid.
Problem on • Swing acceleration is degraded.
machine
• Controller's command (ON/OFF) to swing cut-off solenoid can be checked by using
Related circuit.)
• Swing motor relief pressure is set to "Hi" when solenoid is energized.
• Method of reproducing failure code: Turn starting switch to ON position and perform
hydraulic relief of swing system (with swing lock switch at OFF).

selector solenoid 2. Disconnect connector V04, and connect T-adapters to male side.
1 Between V04 (male) (1) and (2) 20 to 60 z
(internal short circuit or
ground fault) Resistance Between V04 (male) (1) and
ground Min. 1 Mz

Short circuit or ground fault in Between CP02 (female) (93) and
2 wiring harness 20 to 60 z
(115), (117), (120)
Resistance
Between CP02 (female) (93) and
ground Min. 1 Mz
a If no abnormality is found in check on cause 2, this check is not

required.
3 2. Disconnect connectors C02 and V04, and connect T-adapter to
Between ground and CP02
Resistance (female) (93) or between V04 Min. 1 Mz
(female) (1)
40-532 PC360LC-10
40 Troubleshooting
PC360LC-10 40-533
40 Troubleshooting
Failure code [DXA8KA] PC-EPC (F) Sol Open Circuit (PC300-DXA8KA-400-A-Z0-A)
Action level Failure code PC-EPC (Front) Solenoid Open Circuit

Failure
L03 DXA8KA (Pump controller system)
Detail of • No current flows when pump controller drives F-PC-EPC solenoid, so pump controller
failure determines that open circuit exists in F-PC-EPC solenoid circuit.
Problem on • If pump load increases, engine speed decreases largely and engine may stall.
machine
• When solenoid and wiring harness are normal, engine can be prevented from stalling by
setting emergency pump drive switch to ON position.
Related • Drive current to F-PC-EPC solenoid can be checked with monitoring function.
information (Code: 01300 PC-EPC solenoid current (F))
Incorrect operation of
1 Set emergency pump drive switch at its normal position (lower side).
emergency pump drive switch
Defective F-PC-EPC solenoid 2. Disconnect connector V11, and connect T-adapters to male side.
2
3 to 14 z
tance
2. Disconnect connector S25 and connect T-adapters to male side.
Switch position:
Max. 1 z
Defective emergency pump Between S25 (male) Normal
drive switch (3) and (2) Switch position:
3 Min. 1 Mz
Resis- Emergency
(Internal open circuit)
tance Switch position:
Max. 1 z
Between S25 (male) Normal
(6) and (5) Switch position:
Emergency Min. 1 Mz

Open or short circuit in wiring a Check that emergency pump drive switch is at normal position (lower
4
harness side).
Resis- Between CP02 (female) (96) and each of (115),
(117), (120) 3 to 14 z
tance
a If no failure is found by checks on cause 3, this check is not required.
2. Disconnect connectors CP02, S25 and V11, and connect T-adapters
Open circuit in wiring harness to each female side.
Between CP02 (female) (96) and S25 (female)
(3)
Resis- Between S25 (female) (2) and V11 (female) (1) Max. 1 z
(120) and S25 (female) (6) Max. 1 z
Between S25 (female) (5) and V11 (female) (2) Max. 1 z
40-534 PC360LC-10
40 Troubleshooting
Circuit diagram related to PC-EPC solenoid
PC360LC-10 40-535
40 Troubleshooting
Failure code [DXA8KB] PC-EPC (F) Sol Short Circuit (PC300-DXA8KB-400-A-Z0-A)
Action level Failure code PC-EPC (Front) Solenoid Short Circuit

Failure
L03 DXA8KB (Pump controller system)
Detail of • Abnormal current flows when pump controller drives F-PC-EPC solenoid, so pump
failure controller determines that short circuit exists in F-PC-EPC solenoid circuit.
• Stops driving F-PC-EPC solenoid.
machine
Related • Drive current to F-PC-EPC solenoid can be checked with monitoring function.
information (Code: 01300 PC-EPC solenoid current (F))
Defective F-PC-EPC solenoid 1. Turn starting switch to OFF position.

2. Disconnect connector V11, and connect T-adapters to male side.
1 (internal short circuit or
ground fault) Resis- Between V11 (male) (1) and (2) 3 to 14 z
Defective emergency pump
drive switch (internal short Between S25 (male) and each of
2 Switch Min. 1 Mz
circuit or ground fault) Resis- S25 (male) (2) and (3)
position:
tance Between ground and each of S25
Normal Min. 1 Mz
(male) (2) and (3)
Short circuit or ground fault in a Check that emergency pump drive switch is at normal position (lower
3 wiring harness side).
Between CP02 (female) (96) and each of (115),
Resis- (117), (120) 3 to 14 z
tance
Ground fault in wiring harness to any female side.
4
(contact with ground circuit) Between ground and CP02 (female) (96) or
Min. 1 Mz
Resis- S25 (female) (3)
tance Between ground and S25 (female) (5) or V11
40-536 PC360LC-10
40 Troubleshooting
PC360LC-10 40-537
40 Troubleshooting
Failure code [DXA9KA] PC-EPC (R) Sol Open Circuit (PC300-DXA9KA-400-A-Z0-A)
Action level Failure code PC-EPC (Rear) Solenoid Open Circuit

Failure
L03 DXA9KA (Pump controller system)
Detail of • No current flows when pump controller drives R-PC-EPC solenoid, so pump controller
failure determines that open circuit exists in R-PC-EPC solenoid circuit.
machine
Related • Drive current to R-PC-EPC solenoid can be checked with monitoring function.
information (Code: 01302 PC-EPC solenoid current (R))
Incorrect operation of
1 Set emergency pump drive switch at its normal position (lower side).
emergency pump drive switch
Defective R-PC-EPC 1. Turn starting switch to OFF position.
2
3 to 14 z
tance
Switch position:
Max. 1 z
Defective emergency pump Between S25 (male) Normal
drive switch (9) and (8) Switch position:
3 Min. 1 Mz
Resis- Emergency
tance Switch position:
Max. 1 z
Between S25 (male) Normal
(11) and (12) Switch position:
Emergency Min. 1 Mz

Open or short circuit in wiring a Check that emergency pump drive switch is at normal position (lower
4
harness side).
Resis- Between CP02 (female) (104) and each of
(115), (117), (120) 3 to 14 z
tance
Open circuit in wiring harness Between CP02 (female) (104) and S25
5 (wire breakage or defective (female) (9) Max. 1 z
contact of connector) Between S25 (female) (8) and V12 (female) (1) Max. 1 z
Resis-
Between S25 (female) (12) and each of CP02
tance Max. 1 z
(female) (115), (117), (120)
Between S25 (female) (11) and V12 (female)
(2) Max. 1 z
40-538 PC360LC-10
40 Troubleshooting
PC360LC-10 40-539
40 Troubleshooting
Failure code [DXA9KB] PC-EPC (R) Sol Short Circuit (PC300-DXA9KB-400-A-Z0-A)
Action level Failure code PC-EPC (Rear) Solenoid Short Circuit

Failure
L03 DXA9KB (Pump controller system)
Detail of • Abnormal current flows when pump controller drives R-PC-EPC solenoid, so pump
failure controller determines that short circuit exists in R-PC-EPC solenoid circuit.
• Stops driving R-PC-EPC solenoid.
machine
Related • Drive current to R-PC-EPC solenoid can be checked with monitoring function.
information (Code: 01302 PC-EPC solenoid current (R))
Defective R-PC-EPC 1. Turn starting switch to OFF position.
1
Defective emergency pump
drive switch (internal short Between each of S25 (male) (8)
2 Switch Min. 1 Mz
circuit or ground fault) Resis- and (9) and (11)
position:
tance Between each of S25 (male) (8)
Normal Min. 1 Mz
and (9) and ground
Short circuit or ground fault in a Check that emergency pump drive switch is at normal position (lower
3 wiring harness side).
Resis- (115), (117), (120) 3 to 14 z
tance
Ground fault in wiring harness to either female side.
4
(contact with ground circuit) Between CP02 (female) (104) and ground, or
Min. 1 Mz
Resis- between S25 (female) (9) and ground
tance Between ground and S25 (female) (11) or V12
40-540 PC360LC-10
40 Troubleshooting
PC360LC-10 40-541
40 Troubleshooting
Failure code [DXE0KA] LS-EPC Sol Open Circuit (PC300-DXE0KA-400-A-Z0-A)
Action level Failure code LS-EPC Solenoid Open Circuit

Failure
L01 DXE0KA (Pump controller system)
Detail of • No current flows when pump controller drives LS-EPC solenoid, so pump controller
failure determines that open circuit exists in LS-EPC solenoid circuit.
Problem on • Travel speed is high with speed setting at Lo and Mi.
machine • Work equipment speed and swing speed are high in fine control mode (L).
• Drive current to LS-EPC solenoid can be checked with monitoring function.
Related (Code: 01500 LS-EPC solenoid current)
Defective LS-EPC solenoid 2. Disconnect connector V19, and connect T-adapters to male side.
1
3 to 14 z
tance
2
(117), (120) 3 to 14 z
tance
Max. 1 z
Resis- (1)
tance Between V19 (female) (2) and each of CP02
(female) (115), (117), (120) Max. 1 z
40-542 PC360LC-10
40 Troubleshooting
Circuit diagram related to LS-EPC solenoid
PC360LC-10 40-543
40 Troubleshooting
Failure code [DXE0KB] LS-EPC Sol Short Circuit (PC300-DXE0KB-400-A-Z0-A)
Action level Failure code LS-EPC Solenoid Short Circuit

Failure
L01 DXE0KB (Pump controller system)
Detail of • Abnormal current flows when pump controller drives LS-EPC solenoid, so pump controller
failure determines that short circuit exists in LS-EPC solenoid circuit.
• Stops driving LS-EPC solenoid.
Problem on • Travel speed is high with speed setting at Lo and Mi.
machine • Work equipment speed and swing speed are high in fine control mode (L).
• Drive current to LS-EPC solenoid can be checked with monitoring function.
Related (Code: 01500 LS-EPC solenoid current)
Defective LS-EPC solenoid 1. Turn starting switch to OFF position.

2. Disconnect connector V19 and connect T-adapters to male side.
ground fault) Resis- Between V19 (male) (1) and (2) 3 to 14 z
Resis- (117), (120) 3 to 14 z
tance
tance
40-544 PC360LC-10
40 Troubleshooting
Circuit diagram related to LS-EPC solenoid
PC360LC-10 40-545
40 Troubleshooting
Failure code [DXE4KA] Service Current EPC Disc. (PC300-DXE4KA-400-A-Z0-A)
Action level Failure code Service Current EPC Disconnection

Failure
― DXE4KA (Pump controller system)
• No current flows when pump controller drives attachment flow rate adjustment(service
Detail of current) EPC solenoid, so pump controller determines that open circuit exists in
failure attachment flow rate adjustment (service current) EPC solenoid circuit.
Problem on
• Attachment does not move.
machine
• Drive current of attachment flow rate adjustment (service current) EPC solenoid can be
checked with monitoring function.
Related (Code: 01700 Service solenoid current)
information • Method of reproducing failure code: Turn starting switch ON and set machine in breaker
mode (B)
Defective attachment flow 1. Turn starting switch to OFF position.
rate adjustment (service 2. Disconnect connector V30, and connect T-adapters to male side.
1 current) EPC
solenoid (Internal open Resis- Between V30 (male) (1) and (2) 3 to 14 z
circuit) tance
2
(117), (120) 3 to 14 z
tance
Max. 1 z
Resis- (1)
(female) (115), (117), (120) Max. 1 z
Circuit diagram related to attachment flow rate adjustment (service current) EPC solenoid
40-546 PC360LC-10
40 Troubleshooting
Failure code [DXE4KB] Service Current EPC S/C (PC300-DXE4KB-400-A-Z0-A)
Action level Failure code Service Current EPC Short Circuit

Failure
― DXE4KB (Pump controller system)
• Abnormal current flows when pump controller drives attachment flow rate (service
Detail of current) EPC solenoid, so pump controller determines that short circuit exists in
failure attachment flow rate adjustment (service current) EPC solenoid circuit.
• Stops driving attachment flow rate adjustment EPC solenoid.
Problem on
• Attachment does not move.
machine
• Drive current of attachment flow rate adjustment (service current) EPC solenoid can be
Related (Code: 01700 Service solenoid current)
information • Method of reproducing failure code: Turn starting switch to ON position and set machine
in breaker mode (B).
Defective attachment flow 1. Turn starting switch to OFF position.
rate adjustment (service 2. Disconnect connector V30, and connect T-adapters to male side.
1 current) EPC solenoid
Between V30 (male) (1) and (2) 3 to 14 z
(internal short circuit or Resis-
Resis- (117), (120) 3 to 14 z
tance
tance
Circuit diagram related to attachment flow rate adjustment (service current) EPC solenoid
PC360LC-10 40-547
40 Troubleshooting
Failure code [DXE5KA] Merge-divider Main Sol Open Circuit (PC300-DXE5KA-400-A-

Z0-A)
Action level Failure code Merge-divider main solenoid open circuit

Failure
• No current flows when pump controller drives merge-divider (main) EPC solenoid, so
Detail of
pump controller determines that open circuit exists in merge-divider (main) EPC solenoid
failure
circuit.
• Stops output command to merge-divider main solenoid and merge-divider LS solenoid,
Action of and keeps pump always in merged state.
Problem on • Single operation speed of work equipment and swing is high in fine control mode (L).
machine • Machine does not turn easily during travel.
• Drive current to merge-divider main EPC solenoid can be checked with monitoring
Related function.
information (Code: 08000 Merge-divider (main) solenoid current)
Defective merge-divider main 1. Turn starting switch to OFF position.

1 EPC solenoid (internal open 2. Disconnect connector V23, and connect T-adapters to male side.
3 to 14 z
tance
2
harness Resis- Between CP02 (female) (112) and each of
(115), (117), (120) 3 to 14 z
tance
Max. 1 z
Resis- (1)
(female) (115), (117), (120) Max. 1 z
40-548 PC360LC-10
40 Troubleshooting
Circuit diagram related to pump merge-divider main EPC solenoid
PC360LC-10 40-549
40 Troubleshooting
Failure code [DXE5KB] Merge-divider Main Sol Short Circuit (PC300-DXE5KB-400-A-

Z0-A)
Action level Failure code Merge-divider main solenoid short circuit

Failure
• Abnormal current flows when pump controller drives merge-divider (main) EPC solenoid,
Detail of
so pump controller determines that short circuit exists in merge-divider (main)EPC
failure
solenoid circuit.
• Drive current to merge-divider main EPC solenoid can be checked with monitoring
Related function.
information (Code: 08000 Merge-divider (main) solenoid current)
Defective merge-divider main 2. Disconnect connector V23, and connect T-adapters to male side.
1 EPC solenoid (internal short
circuit or ground fault) Resis- Between V23 (male) (1) and (2) 3 to 14 z
2 wiring harness Between CP02 (female) (112) and each of
Resis- (115), (117), (120) 3 to 14 z
tance
tance
40-550 PC360LC-10
40 Troubleshooting
Circuit diagram related to pump merge-divider main EPC solenoid
PC360LC-10 40-551
40 Troubleshooting
Failure code [DXE6KA] Merge-divider LS Sol Open Circuit (PC300-DXE6KA-400-A-Z0-A)
Action level Failure code Merge-divider LS EPC solenoid open circuit

Failure
Detail of • No current flows when pump controller drives merge-divider (LS) EPC solenoid, so pump
failure controller determines that open circuit exists in merge-divider (LS) EPC solenoid circuit.
• Drive current to merge-divider LS EPC solenoid can be checked with monitoring function.
Related (Code: 08001 Merge-divider (LS) solenoid current)
Defective merge-divider LS 1. Turn starting switch to OFF position.

EPC solenoid (internal open 2. Disconnect connector V24, and connect T-adapters to male side.
1
3 to 14 z
tance
2
(117), (120) 3 to 14 z
tance
Max. 1 z
Resis- (1)
(female) (115), (117), (120) Max. 1 z
40-552 PC360LC-10
40 Troubleshooting
Circuit diagram related to merge-divider LS EPC solenoid
PC360LC-10 40-553
40 Troubleshooting
Failure code [DXE6KB] Merge-divider LS Sol Short Circuit (PC300-DXE6KB-400-A-Z0-A)
Action level Failure code Merge-divider LS EPC solenoid short circuit

Failure
• Abnormal current flows when pump controller drives merge-divider (LS) EPC solenoid, so
Detail of
pump controller determines that short circuit exists in merge-divider (LS) EPC solenoid
failure
circuit.
• Drive current to merge-divider LS EPC solenoid can be checked with monitoring function.
Related (Code: 08000 Merge-divider (LS) solenoid current)
Defective merge-divider LS 2. Disconnect connector V24, and connect T-adapters to male side.
1 EPC solenoid (internal short
circuit or ground fault) Resis- Between V24 (male) (1) and (2) 3 to 14 z
Resis- (117), (120) 3 to 14 z
tance
tance
40-554 PC360LC-10
40 Troubleshooting
Circuit diagram related to merge-divider LS EPC solenoid
PC360LC-10 40-555
40 Troubleshooting
Failure code [DY20KA] Wiper Working Abnormality (PC300-DY20KA-400-A-Z0-A)
Action level Failure code Wiper working Abnormality

Failure
– DY20KA (Pump controller system)
Detail of • When windshield wiper works, W signal that indicates that wiper motor reaches working
failure area upper end position is not input.
Action of • Shuts off power supply to wiper motor.
Problem on • Wiper motor does not work.
machine
• Signal input (ON/OFF) of W contact that indicates wiper working area end can be
• Method of reproducing failure code: Turn starting switch to ON and turn wiper switch to
INT or ON position.
2. Disconnect connector M05 and connect T-adapters to female side.
Wiper position:
working area upper Max. 1 z
Defective wiper motor Between M05 (female) end
1
(Internal open circuit) (6) and (5) Wiper position: other
Resistance than working area Min. 1 Mz
upper end
Between M05 (female) Wiper position: whole
(1) and (3) range Max. 20 z

2. Disconnect connectors CP01 and CP02, and connect T-adapters to
each female side.
Wiper position:
working area upper Max. 1 z
Between CP01
Open or short circuit in wiring end
2 (female) (56) and
harness Wiper position: other
ground
Resistance than working area Min. 1 Mz
upper end
Between CP02
Wiper position: whole
(female) (114) and Max. 20 z
range
(119)
2. Disconnect connectors CP01, CP02, and M05.
3. Connect T-adapters to female sides of connectors CP01 and CP02
Open circuit in wiring harness and to male side of M05.
Between CP01 (female) (56) and M05 (male)
(6)
Between M05 (male) (5) and ground (T01) Max. 1 z
Resistance Between CP02 (female) (114) and M05 (male)
(1) Max. 1 z
(3) Max. 1 z
40-556 PC360LC-10
40 Troubleshooting
Circuit diagram related to wiper
PC360LC-10 40-557
40 Troubleshooting
Failure code [DY20MA] Wiper Parking Abnormality (PC300-DY20MA-400-A-Z0-A)
Action level Failure code Wiper Parking Abnormality

Failure
― DY20MA (Pump controller system)
Detail of • When windshield wiper rests, P signal that indicates that wiper motor is at rest area
failure position is not input.
Action of • Stops output for resting to wiper motor.
Problem on • Wiper does not rest.
machine
• Condition of P contact signal of wiper resting area can be checked with monitoring
function.
• Method of reproducing failure code: Turn starting switch to ON position and turn wiper
switch from INT or ON o OFF position.
Wiper position: rest
Defective wiper motor Max. 1 z
Between M05 (female) area
1
(Internal open circuit) (4) and (5) Wiper position:
Resistance working area Min. 1 Mz
Between M05 (female) Wiper position: whole
(1) and (3) range Max. 20 z

2. Disconnect diode arrays CP01 and CP02 and connect T-adapters to
each female side.
Wiper position: rest
Between CP01 Max. 1 z
Open or short circuit in wiring area
2 (female) (75) and
harness Wiper position:
ground Min. 1 Mz
Resistance working area
Between CP02
Wiper position: whole
(female) (114) and Max. 20 z
range
(119)
2. Disconnect connectors CP01, CP02, and M05.
3. Connect T-adapters to female sides of connectors CP01 and CP02
Open circuit in wiring harness and to male side of M05.
(4)
Between M05 (male) (5) and ground (T01) Max. 1 z
Resistance Between CP02 (female) (114) and M05 (male)
(1) Max. 1 z
(3) Max. 1 z
40-558 PC360LC-10
40 Troubleshooting
PC360LC-10 40-559
40 Troubleshooting
Failure code [DY2CKB] Washer Drive Short Circuit (PC300-DY2CKB-400-A-Z0-A)
Action level Failure code Window washer drive system short circuit
Failure
― DY2CKB (Pump controller system)
Detail of • When driving window washer motor, abnormal current flows and short circuit is detected.
failure
• Shuts of power supply to washer motor.
Problem on • Window washer does not operate.
machine
Related • Method of reproducing failure code: Turn starting switch to ON position and turn on
information washer switch.
Defective fuse No. 4 in fuse If fuse is blown, circuit probably has ground fault, etc. (See failure code
1 [DY2CKA].)
box F01
Defective washer motor 2. Disconnect connector M06 and connect T-adapters to male side.
2 (internal open circuit or Between M06 (male) (1) and (2) Approx. 10
ground fault) Resis- z
tance Between M06 (male) (1) and ground, or
between M06 (male) (2) and ground Min. 1 Mz

2. Disconnect connector D02 and connect T-adapters to male side.
Defective diode array D02 a Check by using multimeter in diode range.
3
(internal short circuit) Between D02 (male) (6) (+) and (2) (-) Continuity
Continuity No
continuity
Open or short circuit in wiring 3. Turn starting switch to ON position.
4
harness
a Ignore failure codes displayed on machine monitor.
Voltage Between CP01 (female) (3) and ground 20 to 30 V
2. Disconnect fuse No. 4 of fuse box F01.
Ground fault in wiring harness 3. Disconnect connectors M06, CP01, and D02, and connect T-
5 adapters to any one of female sides.
Between ground and any one of F01 (4), M06
Min. 1 Mz
Resis- (female) (2), or D02 (female) (2)
tance Between ground and any one of CP01 (female)
(3), M06 (female) (1), or D02 (female) (6) Min. 1 Mz

2. Disconnect connectors CP01 and M06, and connect T-adapter to
Hot short circuit in wiring female side of CP01.
6 harness 3. Remove fuse No. 4.
a Ignore failure codes displayed on machine monitor.
Voltage Between CP01 (female) (3) and ground Max. 1 V
40-560 PC360LC-10
40 Troubleshooting
Circuit diagram related to window washer motor
PC360LC-10 40-561
40 Troubleshooting
Failure code [DY2DKB] Wiper Drive (For) Short (PC300-DY2DKB-400-A-Z0-A)
Action level Failure code Wiper motor drive normal rotation system short circult
Failure
― DY2DKB (Pump controller system)
Detail of • When normal rotation command to power wiper motor drive is ON, abnormal current flows
failure through circuit and short circuit is detected.
• Shuts off power supply to normal rotation system of wiper motor drive.
Problem on • Windshield wiper does not operate.
machine
information • Method of reproducing failure code: Turn starting switch to ON position and turn wiper
switch to INT or ON position.
Defective wiper motor 1. Turn starting switch to OFF position.

ground fault) Resis- Between M05 (female) (3) and (1) Max. 20 z
tance Between M05 (female) (3) and ground Min. 1 Mz
2. Disconnect connectors CP02 and M05 and connect T-adapter to
2 Short circuit in wiring harness either harness side.
Resis- Between CP02 (female) (119) and (114), or
between M05 (male) (1) and (3) Min. 1 Mz
tance
Ground fault in wiring harness 2. Disconnect connectors CP02 and M05 and connect T-adapter to
3 either harness side.
Resis- Between CP02 (female) (119) and ground, or
tance
• Reference
2. Insert T-adapters into connector M05.
4 Defective pump controller 3. Turn starting switch to ON position.
4. Turn wiper switch ON and OFF for troubleshooting.
Wiper
Between M05 (3) and switch: Max. 3 V
Voltage OFF
(5)
Wiper Pulse below 3 V io
switch: ON above 20 V
40-562 PC360LC-10
40 Troubleshooting
PC360LC-10 40-563
40 Troubleshooting
Failure code [DY2EKB] Wiper Drive (Rev) Short (PC300-DY2EKB-400-A-Z0-A)
Action level Failure code Wiper motor drive reverse rotation system short circuit
Failure
― DY2EKB (Pump controller system)
Detail of • When reverse rotation command to wiper motor drive is ON, abnormal current flows
failure through circuit and short circuit is detected.
• Shuts off power supply to reverse rotation system of wiper motor drive.
Problem on • Windshield wiper does not operate.
machine
information • Method of reproducing failure code: Turn starting switch to ON position and turn wiper
switch to INT or ON position.

ground fault) Resis- Between M05 (female) (1) and (3) Max. 20 z
tance Between M05 (female) (1) and ground Min. 1 Mz
2. Disconnect connectors CP02 and M05 and connect T-adapter to
2 Short circuit in wiring harness either harness side.
Resis- Between CP02 (female) (119) and (114), or
between M05 (male) (1) and (3) Min. 1 Mz
tance
Ground fault in wiring harness 2. Disconnect connectors CP02 and M05 and connect T-adapter to
3 either harness side.
Resis- Between CP02 (female) (114) and ground, or
tance
• Reference
2. Insert T-adapters into connector M05.
4 Defective pump controller 3. Turn starting switch to ON position.
4. Turn wiper switch ON and OFF for troubleshooting.
Wiper
Between M05 (1) and switch: Max. 3 V
Voltage OFF
(5)
Wiper Pulse below 3 V io
switch: ON above 20 V
40-564 PC360LC-10
40 Troubleshooting
PC360LC-10 40-565
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
Troubleshooting of electrical system (E-mode) (ALL-3840-001-A-01-A)
E-1 Engine does not start (Engine does not crank) (PC300-A21-400-A-Z0-A)
Failure • Engine does not start (engine does not crank)

• Engine starting circuit has following two start lock mechanisms.
1. Start lock by password protection of machine monitor
2. Start lock by lock lever position
Related information • If failure symptom "Battery relay operation sound is not heard" appears when
starting switch is turned to ON position, perform troubleshooting for E-1 also.
• If failure symptom is "Machine monitor displays nothing" when starting switch is
turned to ON position, main electric power supply system may be defective. So,
perform troubleshooting for E-5 (lines connecting to fusible link F05 and fuse No 17).
Loose terminal connection or 1. Turn starting switch to OFF position.

1 open circuit at terminal Check terminals of starting motor, alternator, battery relay, grounds T04
and T08, etc.
Between battery relay terminal R01 and
Defective contact (grounding) ground
2 between battery relay and Resis-
frame a Use machine frame as GND for Max. 1 z
tance
measurement.
a Loosened or rusted terminal T08
a Be ready with starting switch at OFF, then perform troubleshooting
Insufficient battery capacity without turning starting switch to ON position.
3
Battery voltage (two pieces) Min. 24 V
Electrolyte specific gravity (each) Min. 1.26
Defects of engine controller power supply and ACC signal are indicated
Defective engine controller
4 with failure codes [DB2QKR] and [DB2RKR]. If these codes appear,
system
perform troubleshooting for causes 1 to 3 of [DB2QKR] first.
Defective fuse No. 3 in fuse If fuse is blown, circuit probably has ground fault. (See cause 22.)
5
box F01
1. Turn starting switch to ON position (to connect ACC).
6 Defective battery relay system
a If battery relay operation sound is not heard, go to troubleshooting
on cause 19.
1. Turn starting switch to OFF position, and remove fuse No. 3 in fuse
box F01.
Defective fusible link F04 or 2. Turn starting switch to ON position (to connect ACC).
7 wiring harness Between input terminal (1A) of fuse box F01-3
Voltage 20 to 30 V
and ground
a If voltage is unusual, go to troubleshooting on cause 10.
2. Remove fuse No. 18 (30 A) of fuse box F01. (to prevent engine start
Defective starting switch, lock during troubleshooting).
lever switch, starting motor 3. Insert T-adapters into connector M17.
8 cut-off relay R06, personal 4. Turn starting switch to START position and hold (two persons
code relay R07, battery relay, required for this check).
or wiring harness Voltage Between M17 (1) and ground 20 to 30 V
a If voltage is unusual, go to cause 13.
40-566 PC360LC-10
40 Troubleshooting

If fusible link is blown, circuit may have ground fault. In this case,
perform troubleshooting for cause 6 first.
9 Defective fusible link F04 • Fuses No. 1 to 13 are connected to fusible link F04.
a This fusible link protects wide area of circuit. If no failure is found by
check on cause 6, reproduce failure and locate ground fault point by
sound and burnt smell.
Open circuit in wiring harness switch to OFF position.
1 (To prevent short circuit during troubleshooting)
10 2. Disconnect fusible link F04 and No. 3 of fuse box F01.
contact of connector) 3. Connect T-adapters to male side of connector F04.
Between battery relay (R03) and F04 (male)
Resis- (1) Max. 1 z
tance
Between F04 (male) (2) and F01-1A Max. 1 z
Ground fault in wiring harness 2. Disconnect fusible link F04, fuse No. 3 of fuse box F01, and battery
11 1 relay R03 (M terminal).
(contact with ground circuit) 3. Connect T-adapters to male side of connector F04.
Between ground and battery relay R03
Resis- (harness side) or F04 (male) (1) Min. 1 Mz
tance
Between ground and F04 (male) (2) or F01-1A Min. 1 Mz
2. Disconnect connector H15 and connect T-adapters to male side.
3. After troubleshooting, perform troubleshooting again with starting
switch at ON and START positions.
Turn starting switch to
OFF position. Min. 1 Mz
Between H15 (male)
Defective starting switch (1) and (2) Turn starting switch to
12 ON position. Max. 1 z
OFF position. Min. 1 Mz
Resis- Between H15 (male)
tance (1) and (5) Turn starting switch to
ON position. Max. 1 z
Between H15 (male) OFF position. Min. 1 Mz
(1) and (4) Starting switch:
Max. 1 z
START
Defective lock lever switch 1. Turn starting switch to OFF position.
13 2. Disconnect connector S14 and connect T-adapters to female side.
Resis- Between S14 (female) Lock lever: FREE Min. 1 Mz
tance (1) and (3) Lock lever: LOCK Max. 1 z
PC360LC-10 40-567
40 Troubleshooting

2. Remove starting motor cut-off relay R06 and personal code relay
Defective starting motor cut- R07.
off relay R06 or personal code Between R06 (male) (1) and (2) 200 to 600
z
14 relay R07
Between R06 (male) (3) and (4) Max. 1z
circuit) Resis- Between R06 (male) (3) and (5) Min. 1 Mz
tance Between R07 (male) (1) and (2) 200 to 600
z
Between R07 (male) (3) and (4) Max. 1 z
Between R07 (male) (3) and (5) Min. 1 Mz
Defective alternator 2. Turn starting switch to ON position.
15 Input from
(internal short circuit) Between alternator M18 terminal
Voltage alternator Max. 1 V
and ground
generation
2. Turn starting switch to START position and perform troubleshooting.
Between starting motor terminal B Power
(SB) and ground supply 20 to 30 V
Defective starting motor
16 Voltage Starting
(internal defect) Between starting motor terminal C input to
(SC) and ground 20 to 30 V
starting
motor
If power supply and starting input to starting motor are normal but
starting motor does not rotate, starting motor is defective.
2. Disconnect connector D01 and connect T-adapters to diode.
Defective diode D01 a Check by using multimeter in diode range.
17 (internal open circuit or shortBetween D01 (male) (1) (+) and (5) (-) No continuity
circuit) Between D01 (male) (5) (+) and (1) (-) Continuity
• Battery relay
Resis- Between terminal R02 and H15 (female) (2)
Max. 1 z
tance
• Battery relay
18 (wire breakage or defective 2. Turn starting switch to ON position.
contact of connector) a To check to where 24 V is supplied to locate open section
Between terminals R04 and R01 20 to 30 V
Voltage
Between terminal R01 and ground Max. 1 V
40-568 PC360LC-10
40 Troubleshooting

• Alternator and starting motor
2. Turn battery disconnect switch to OFF position.
3. Insert T-adapters into connectors H15, S14, R07, and M17.
5. Turn starting switch to START position and perform troubleshooting.
a To check to where 24 V is supplied to locate open section
Between H15 (4) and ground 20 to 30 V
Between S14 (1) and ground 20 to 30 V
Between S14 (3) and ground 20 to 30 V
Voltage Between R07 (4) and ground 20 to 30 V
Between M17 (1) and ground 20 to 30 V
Between alternator B terminal and ground 20 to 30 V
Between starting motor terminal B and ground 20 to 30 V
• If fuse or fusible link is blown, replace it with a new one.
2. Disconnect connectors H15, S14, R06, R07, and CM01.
3. Connect T-adapters to female sides of H15, R06, R07, CM01 and to
Open circuit in wiring harness male side of S14.
18 (wire breakage or defective 4. Remove fuse F01-3.
contact of connector) Between H15 (female) (4) and R06 (female)
(3) Max. 1 z
Between R06 (female) (5) and R07 (female)
(3) Max. 1 z
Between R07 (female) (1) and S14 (male) (1) Max. 1 z
Between R07 (female) (2) and CM01 (female)
(6) Max. 1 z
Between R07 (female) (4) and starting motor
Max. 1 z
terminal S
Resis- Between alternator terminal B and starting Max. 1 z
tance motor terminal B
Between starting motor B and battery relay
Max. 1 z
R03
Between alternator terminal R (terminal M18)
and starting motor terminal R Max. 1 z
Between alternator terminal R and D01
Between F01-3 and S14 (male) (1) Max. 1 z
Between S14 (male) (3) and R06 (male) (1) Max. 1 z
Between R06 (female) (2) and ground (T05) Max. 1 z
Defective battery relay If only terminal R03 voltage is unusual among results of battery relay
19 checks on cause 18, battery relay is defective.
(does not turn ON)
2. Disconnect connectors H15, S14, R06, R07, and M17.
3. Connect T-adapters to female sides of H15, R06 and R07, and to
male side of S14.
4. Remove fuse No. 3 of fuse box F01.
Between ground and H15 (female) (4) or R06
20 Between ground and R06 (female) (5) or R07
(contact with ground circuit) Min. 1 Mz
(female) (3)
Resis- Between ground and R07 (female) (4) or M17
tance (female) (1) Min. 1 Mz
Between ground and F01-3 or S14 (male) (1) Min. 1 Mz
Between ground and S14 (male) (3) or R06
PC360LC-10 40-569
40 Troubleshooting

2. Insert T-adapters into connector M17 or CM01.
Voltage Between ground and M17 (2) or CM01 (16) Max. 1 V
40-570 PC360LC-10
40 Troubleshooting
Circuit diagram related to engine start circuit
PC360LC-10 40-571
40 Troubleshooting
E-2 Manual preheating does not work (PC300-FEM-400-A-Z0-A)
Failure Manual preheater does not operate

a This troubleshooting describes procedures to be followed when manual preheating
does not function to heat electrical intake air heater (ribbon heater) mounting
section.
• This machine has “Automatic preheating” and “Manual preheating” functions. When
either preheating works, preheating monitor lights up. (When only preheating
monitor does not light up, perform troubleshooting for failure symptom "While
Related information preheating is working, preheating monitor does not light up").
• If failure symptom "Machine monitor displays nothing" or "Battery relay does not
make operating sound" appears when turning starting switch to ON position, main
electric power supply system is supposed to be defective. In these cases, perform
troubleshooting for E-5 and E-1 respectively.
• If fuse No. 17 in fuse box F01 is blown, perform troubleshooting for "Machine
monitor displays nothing".
• Before performing troubleshooting, check that no related failure code is displayed.
Loose terminal or open circuit
1 Check terminals of heater relay, battery relay, electrical intake air
at terminal
heater (ribbon heater), etc.
If the fuse is blown, the circuit probably has a ground fault or any other
2 Defective fuse FL (80 A)
fault. (See cause 8)
2. Disconnect connectors CM01 and H15, and connect T-adapter to
female side of H15.
Resis- Between H15A (female) (3) and ground (to Approx. 20
tance measure heater relay coil resistance) z
• Secondary side
Between R17 (heater relay input terminal on
Voltage 20 to 30 V
contact side) and ground
Open circuit or ground fault in • Primary side
3 wiring harness 1. Turn starting switch to OFF position.
2. Disconnect heater relay terminal R16.
a To prevent current from flowing through heater when starting
switch is turned to HEAT position
3. Turn starting switch to HEAT position (Connect R1).
Voltage Between heater relay terminal R15 and ground 20 to 30 V
2. Disconnect heater relay terminal R16.
Between R16 (wiring harness side)
Continuity Continuity
and ground
a If no failure is found by check on primary side on cause 3, this check
is not required.
Defective diode D02 2. Disconnect connector D02 and connect T-adapters to diode.
4 (internal open circuit or short a Check by using multimeter in diode range.
circuit)
Between D02 (male) (1) (+) and (5)
No continuity
(-)
Continuity
Between D02 (male) (5) (+) and (1)
Continuity
(-)
40-572 PC360LC-10
40 Troubleshooting

a If no failure is found by check on primary side on cause 3, this check
is not required.
2. Turn battery disconnect switch to OFF position.
5 Defective starting switch 3. Disconnect connector H15 and connect T-adapters to male side.
4. Turn starting switch to OFF/HEAT position and perform
troubleshooting .
Resis- Between H15 (male) (1) and (3) OFF Min. 1 Mz
tance HEAT Max. 1 z
Defective electrical intake air 1. Turn starting switch to OFF position.
6 heater (ribbon heater) 2. Disconnect terminal E01.
(Internal open circuit) Continuity Between E01 terminal and ground Continuity
Defective heater relay
If no failure is found by check on cause 3 and heater relay operation
7 (Does not work) (Terminal sound is not heard, heater relay is defective.
R16)
2. Disconnect connectors H15A, CM01, D02, terminals R15, E01, and
starting motor B terminal.
Ground fault in wiring harness Between heater relay terminal R15 (wiring
8 Min. 1 Mz
(contact with ground circuit) harness side) and ground
Resis- Between heater relay R17 (input terminal on
contact side) and ground Min. 1 Mz
tance
Between heater relay terminal E01 (wiring
harness side) and ground Min. 1 Mz
PC360LC-10 40-573
40 Troubleshooting
Circuit diagram related to preheating of engine
40-574 PC360LC-10
40 Troubleshooting
E-3 Automatic preheating system does not work (PC300-FE1-400-A-Z0-A)
Failure Automatic preheater does not operate

• Automatic preheater operates when engine coolant temperature is below -5 °C .
(Monitoring code Engine coolant temperature: 04107)
• If automatic preheating does not function, check if manual preheating functions.
Related • Engine controller checks primary (coil) side of preheater relay (connector R18) and
information generates failure codes [CA2555] and [CA2556] if it is defective.
• Engine controller is in charge of detection of failure in engine coolant temperature
sensor and generates failure code [CA144] or [CA145].
Defective fuse No. 6 in If fuse No. 6 in fuse box F01 is blown, ground fault may have occurred in
1 circuit. In this case, perform checks on cause 5 first.
fuse box F01
2. Replace preheater relay (connector R18) with horn relay (connector
Defective preheater relay
R08), for example.
2 R18 (internal open or
short circuit)
If automatic preheater operates when engine coolant temperature is below
-5 °C , original preheater relay is defective.
2. Disconnect connectors CM01, R18, and D02, and connect T-adapters to
female side of R18.
Open circuit or ground a If resistance is above 1 Mz , wiring harness has open circuit. If
3 fault in wiring harness resistance is below 1 z , wiring harness has short circuit.
a Heater relay coil resistance
Approx. 20
Resistance Between R18 (female) (5) and ground
z
Open circuit in wiring 2. Disconnect connectors R18 and CM01, and connect T-adapters to
harness female side of R18.
4 (wire breakage or 3. Remove fuse No. 6 in fuse box F01.
defective contact of Between R18 (female) (3) and F01-6 Max. 1 z
connector) Resistance Between R18 (female) (5) and heater relay
Max. 1 z
terminal R15
If fuse is not blown, this check is not required.
5 2. Disconnect connector R18 and connect T-adapters to female side.
circuit)
Resistance Between R18 (female) (3) and ground Min. 1 Mz
PC360LC-10 40-575
40 Troubleshooting
40-576 PC360LC-10
40 Troubleshooting
E-4 While preheating is working, preheating monitor does not light

up (PC300-FE2-400-A-Z0-A)
Failure While preheater is operating, preheating monitor does not light up
• "Automatic preheating" and "Manual preheating" functions are available. When either
Related function is operated, preheating monitor lights up.
information • Check if manual preheating functions first.
harness 2. Disconnect connectors H15, CM01, and R18, and connect T-adapters to
1 (wire breakage or each female side.
defective contact of Between H15 (female) (3) and CM01 (female) (12) Max. 1 z
Between R18 (female) (5) and CM01 (female) (12) Max. 1 z
• Reference
2. Insert T-adapter into connector CM01.
Defective machine 3. Disconnect heater relay terminal R16.
2
monitor
a To prevent current from flowing through heater when starting switch is
turned to HEAT position
4. Turn the starting switch to HEAT position.
Resistance Between CM01 (12) and (3) 20 to 30 V
PC360LC-10 40-577
40 Troubleshooting
40-578 PC360LC-10
40 Troubleshooting
E-5 When starting switch is turned to ON position, machine monitor

displays nothing (PC300-FEG-400-A-Z0-A)
Failure • When starting switch is turned to ON position, machine monitor displays nothing.
• When starting switch is turned to ON position, machine monitor displays KOMATSU
logo screen, password input screen (if set), breaker mode confirmation screen (if
selected), check before starting screen, working mode and travel speed
Related information confirmation screen, and standard screen in order.
• When engine is started, battery voltage may lower suddenly, depending on ambient
temperature and condition of battery.
Battery disconnect switch left Turn starting switch to OFF position and check that battery disconnect
1 in OFF position switch is in ON position.
a Be ready with starting switch at OFF, then perform troubleshooting
without turning starting switch to ON position.
Battery
voltage
(two Min. 24 V
2 Insufficient battery capacity
pieces)
Electrolyte
specific
gravity Min. 1.26
(each)
If fusible link is broken, circuit probably has grounding fault. (See
3 Defective fusible link F05 Cause 9.)
If the fuse is broken, the circuit probably has a grounding fault. (See
4 Defective fuse F01-15 Cause 9.)
If the fuse is broken, the circuit probably has a grounding fault. (See
5 Defective fuse F01-17 Cause 9.)
Loose terminal or open circuit 1. Turn starting switch to OFF position.
6
at terminal Check terminals of battery relay, etc.
2. Insert T-adapter into connector CM01.
Defective wiring harness, 3. Turn battery disconnect switch to ON position, and turn starting
7 starting switch, or machine switch to ON position (to connect ACC).
monitor Between CM01 (1) and (3) 20 to 30 V
Voltage Between CM01 (2) and (4) 20 to 30 V
2. Disconnect connector H15 and connect T-adapters to male side.
3. Turn starting switch to ON position and perform troubleshooting
Defective starting switch again.
8
(Internal open circuit) Between H15 (male) Turn starting switch to
Min. 1 Mz
Resis- (1) and (5) OFF position.
tance Between H15 (male) Turn starting switch to
(1) and (5) ON position. Max. 1 z
PC360LC-10 40-579
40 Troubleshooting

If no failure is found by check on cause 7, this check is not required.
2. Disconnect fusible link F05, No. 15 and 17 fuses of F01, and
connectors H15 and CM01.
3. Connect T-adapters to male side of connector F05 and female side
of H15 and CM01.
Between battery (-) and ground Max. 1 z
Open circuit in wiring harness Between battery (+) and F05 (male) (1) Max. 1 z
9
(Internal open circuit) Between F05 (male) (2) and F01-16F Max. 1 z
Between F01-17 and each of CM01 (female)
Max. 1 z
Resis- (1) and (2)
tance Between ground (T04) and each of CM01
(female) (3) and (4) Max. 1 z
Between F01-17 and H15 (female) (1) Max. 1 z
Between H15 (female) (5) and F01-15E Max. 1 z
Between F0-15 and CM01 (female) (10) Max. 1 z
If no failure is found by checks on causes 3 to 5 and 7, this check is not
required.
2. Disconnect fusible link F05, No. 17 of fuse box F01, terminal 14D,
and connectors H15, CM01, and CP01.
3. Connect T-adapters to male side of connector F05 and female side
of H15 and CM01.
10 Between battery (+) or F05 (male) (1) and
(contact with ground circuit) ground Min. 1 Mz
Between ground and F05 (male) (2) or F01-
Min. 1 Mz
16F
Resis- Between F01-17 and ground, or between
tance CM01 (female) (1), (2) and ground, or between Min. 1 Mz
H15 (female) (1) and ground
Between ground and H15 (female) (5) or CM01
40-580 PC360LC-10
40 Troubleshooting
Circuit diagram related to machine monitor power supply
PC360LC-10 40-581
40 Troubleshooting
E-6 While starting switch is turned to ON position (with engine stopped),

engine oil level monitor lights up in yellow (PC400-FEJ-400-A-Z0-A)
While starting switch is turned to ON position (with engine stopped), engine oil level
Failure monitor lights up in yellow.
Related information
Defective engine oil level
1 switch system (machine Perform troubleshooting for failure code [B@BAZK].
monitor system)
If no failure is found by check on cause 1, machine monitor may be
2 Defective machine monitor defective.
40-582 PC360LC-10
40 Troubleshooting
E-7 While starting switch is turned to ON position (with engine stopped),

radiator coolant level monitor lights up in yellow (PC400-FEH-400-A-Z0-A)
While starting switch is turned to ON position (with engine stopped), radiator coolant
Failure level monitor lights up in yellow.
Related information
Low radiator coolant level Coolant level may be low. Check coolant level and add coolant if
1
(when system works properly) necessary.
Radiator sub tank coolant
2 Perform troubleshooting for failure code [B@BCZK].
level switch system
PC360LC-10 40-583
40 Troubleshooting
E-8 Engine coolant temperature monitor lights up in white while engine

is running (PC400-FES-400-A-Z0-A)
Failure Engine coolant temperature monitor lights up in white while engine is running
• Signal of engine coolant temperature sensor is input to engine controller and then
data is transmitted to machine monitor through CAN communication system.
Related information • Engine coolant temperature can be checked with monitoring function
(Code: 04107)
If monitor lights up in white, engine coolant temperature may be low
Insufficient warm-up of
(below approximately 30 °C ). Warm up engine.
1 machine
• Lighting up in white: Engine coolant temperature is low.
(when system works properly)
• Lighting up in blue: Engine coolant temperature is proper.
If no failure is found by above diagnoses, engine coolant temperature
gauge system may be defective. Carry out troubleshooting for the
following failures.
2 temperature gauge system • E-18 Engine coolant temperature gauge display does not move
from minimum or maximum
• E-19 Display of engine coolant temperature gauge differs from
actual coolant temperature (reading not at minimum or maximum)
40-584 PC360LC-10
40 Troubleshooting
E-9 Hydraulic oil temperature monitor lights up in white while engine is

running (PC400-FEU-400-A-Z0-A)
Failure Hydraulic oil temperature monitor lights up in white while engine is running
• Signal of hydraulic oil temperature sensor is input to pump controller and then data
is transmitted to machine monitor through CAN communication system.
Related information • Hydraulic oil temperature can be checked with monitoring function
(Code: 04401)
If monitor lights up in white, hydraulic oil temperature may be low
Insufficient warm-up of
(below approximately 20 °C ). Warm up engine.
1 machine
• Lighting up in white: Hydraulic oil temperature is low.
• Lighting up in blue: Hydraulic oil temperature is proper.
If no failure is found by above diagnoses, hydraulic oil temperature
following failures.
2 temperature gauge system • E-20 Hydraulic oil temperature gauge display does not move from
minimum or maximum
• E-21 Display of hydraulic oil temperature gauge differs from actual
oil temperature (reading not at minimum or maximum)
PC360LC-10 40-585
40 Troubleshooting
E-10 Charge level monitor lights up in red while engine is running (PC400-FEP-
400-A-Z0-A)
Failure Charge level monitor lights up in red while engine is running

• Power generation voltage of alternator can be checked with monitoring function.
Related information (Code: 04300)

1 Defective alternator system Perform troubleshooting for failure code [AB00KE].
40-586 PC360LC-10
40 Troubleshooting
E-11 Fuel level monitor lights up in red while engine is running (PC400-FEQ-400-A-
Z0-A)
Failure Fuel level monitor lights up in red while engine is running

• Signal voltage of fuel level sensor can be checked with monitoring function.
Low fuel level
1 Fuel level may be low. Check it and add fuel if necessary.
If no failure is found by above diagnoses, fuel gauge system may be
defective. Carry out troubleshooting for the following failures.
Defective fuel level gauge
2 system • E-16 Fuel gauge display does not move from minimum or maximum
• E-17 Display of fuel gauge differs from actual fuel level (reading not
at minimum or maximum)
PC360LC-10 40-587
40 Troubleshooting
E-12 Air cleaner clogging monitor lights up in yellow while engine is

running (PC400-FER-400-A-Z0-A)
Failure Air cleaner clogging monitor lights up in yellow while engine is running
• Air cleaner clogging switch signal can be checked with monitoring function.
Related information (Code 04501)
Clogging of air cleaner Air cleaner may be clogged. Check it, then clean or replace if
1
(when system works properly) necessary.
Defective air cleaner clogging
2 Perform troubleshooting for failure code [AA10NX].
switch system
40-588 PC360LC-10
40 Troubleshooting
E-13 Engine coolant temperature monitor lights up in red while engine is

running (PC400-FET-400-A-Z0-A)
Failure Engine coolant temperature monitor lights up in red while engine is running
• Signal voltage of engine coolant temperature sensor is input to engine controller and
then data is transmitted to machine monitor through CAN communication system.
(Code: 04107)
If monitor lights up in red, engine coolant temperature may be high
(above approximately 102 °C ). Cool down engine coolant (run engine
at low idle).
Overheating of engine coolant • Lighting up in red: Engine coolant temperature is high
1 (overheating).
• Lighting up in blue: Engine coolant temperature is proper.
Perform troubleshooting for "S-17 Coolant temperature becomes too
high (overheating)".
If no failure is found by above diagnoses, engine coolant temperature
following failures.
2 temperature gauge system • E-18 Engine coolant temperature gauge display does not move
PC360LC-10 40-589
40 Troubleshooting
E-14 Hydraulic oil temperature monitor lights up in red while engine is

running (PC400-FEV-400-A-Z0-A)
Failure • Hydraulic oil temperature monitor lights up in red while engine is running
• Signal of hydraulic oil temperature sensor is input to pump controller and then the
data is transmitted to machine monitor through CAN communication system.
(Code: 04401)
If monitor lights up in red, hydraulic oil temperature may be high (above
approximately 102 °C ). Cool down hydraulic oil (run engine at low idle
Overheating of hydraulic oil
1 or stop engine).
• Lighting up in red: Hydraulic oil temperature is high (overheating).
• Lighting up in blue: Hydraulic oil temperature is proper.
If no failure is found by above diagnoses, hydraulic oil temperature
following failures.
2 temperature gauge system • E-20 Hydraulic oil temperature gauge display does not move from
minimum or maximum
• E-21 Display of hydraulic oil temperature gauge differs from actual
oil temperature (reading not at minimum or maximum)
40-590 PC360LC-10
40 Troubleshooting
E-15 Engine oil pressure monitor lights up in red while engine is

running (PC400-FEW-400-A-Z0-A)
Failure Engine oil pressure monitor lights up in red while engine is running
• Signal of engine oil pressure sensor is input to engine controller and then the data is
transmitted to machine monitor through CAN communication system.
Related information • Engine oil pressure can be checked with monitoring function.
• (Code: 37200)
Low of engine oil pressure Check engine oil pressure as low engine oil pressure is detected.
1
(when system works properly) • Perform troubleshooting "S-14 (Oil pressure decreases)".
If no failure is found by checks on cause 1, engine oil pressure sensor
Defective engine oil pressure
2 system may be defective. Perform troubleshooting for failure codes
system
[CA135] and [CA141].
If causes 1 - 2 are not cause for trouble, machine monitor may be
PC360LC-10 40-591
40 Troubleshooting
E-16 Fuel gauge display does not move from minimum or maximum (PC400-
FGE-400-A-Z0-A)
1) While fuel is added, fuel level gauge indicator does not rise above red range (E).
Failure 2) While fuel level is low, fuel level gauge indicator does not lower below green range
top (F).
Defective fuel level sensor 2. Disconnect connector P21 and connect T-adapters to male side.
1 tor (internal open or short Approx. 12
Fuel level: FULL
circuit) Resis- Between P21 (male) z
tance (1) and ground 85 to 110
Fuel level: EMPTY
z
2. Disconnect connector CM01 and connect T-adapters to female
Open circuit or short circuit in side.
2 wiring harness Approx. 12
Between CM01 Fuel level: FULL
Resis- (female) (15) and z
tance ground 85 to 110
Fuel level: EMPTY
z
3 (wire breakage or defective 2. Disconnect connectors CM01 and P21, and connect T-adapters to
Resis- Between CM01 (female) (15) and P21 (female)
(1) Max. 1 z
tance
Ground fault in wiring harness 2. Disconnect connectors CM01 and P21, and connect T-adapters to
Resis- Between ground and CM01 (female) (15) or
tance
Hot short circuit in wiring 3. Insert T-adapters into connector CM01 or connect T-adapters to
5 harness female side of connector P21.
circuit) 4. Turn starting switch to ON position.
Between ground and CM01 (15) or P21 Approx.
Voltage
(female) (1) 3.3 V
Circuit diagram related to fuel level sensor
40-592 PC360LC-10
40 Troubleshooting
E-17 Display of fuel gauge differs from actual fuel level (PC400-FGF-400-A-Z0-A)
1) Indication of fuel level gauge is different from actual fuel level.

Failure
2) Indication of fuel level gauge is different from display of fuel level monitor.
1 Defective fuel level sensor See previous page.
a Turn starting switch to ON position or start engine and perform
troubleshooting.
Fuel level 511 l Fuel gauge level 6
Color of Fuel level 295 l Fuel gauge level 4 Blue
monitor (a) Fuel level 148 l Fuel gauge level 3
Fuel level 76 l Fuel gauge level 1 Red
Fuel level gauge and fuel level monitor
PC360LC-10 40-593
40 Troubleshooting
E-18 Engine coolant temperature gauge display does not move from
minimum or maximum (PC400-FGG-400-A-Z0-A)
1) While engine coolant temperature is rising properly, temperature gauge indicator
does not rise above white range (C).
Failure
2) While engine coolant temperature remains in normal range, temperature gauge
indicator rises to red range (H).
(Code: 04107)
Defective engine coolant Engine coolant temperature sensor system may be defective. Perform
1 temperature sensor system troubleshooting for failure codes [CA144] and [CA145].
40-594 PC360LC-10
40 Troubleshooting
E-19 Display of engine coolant temperature gauge differs from actual

coolant temperature (PC400-FGH-400-A-Z0-A)
1) Indication of the engine coolant temperature gauge is different from actual coolant
temperature.
Failure
2) Display of engine coolant temperature gauge is different from display of engine
coolant temperature monitor.
(Code: 04107)
Defective engine coolant Engine coolant temperature sensor system may be defective. Perform
1 temperature sensor system troubleshooting for failure codes [CA144] and [CA145].
troubleshooting.
Engine coolant
Coolant temperature
temperature gauge
105 °C
level 6
Red
Engine coolant
Coolant temperature
temperature gauge
102 °C
level 5
Engine coolant
Coolant temperature
2 Defective machine monitor temperature gauge
Color of 100 °C
level 4
monitor (a) Engine coolant
Coolant temperature
temperature gauge Blue
85 °C
level 3
Engine coolant
Coolant temperature
temperature gauge
60 °C
level 2
Engine coolant
Coolant temperature
temperature gauge White
30 °C
level 1
Engine coolant temperature gauge and coolant temperature monitor
PC360LC-10 40-595
40 Troubleshooting
E-20 Hydraulic oil temperature gauge display does not move from
minimum or maximum (PC400-FGJ-400-A-Z0-A)
1) While hydraulic oil temperature is rising properly, temperature gauge does not rise
from white range (C).
Failure
2) While hydraulic oil temperature is stabilized properly, temperature gauge rises to red
range (H).
(Code: 04401)
Approx. 90
10 °C
kz
Defective hydraulic oil Approx. 35
Between P22 (male) (1) and (2) 30 °C
1 temperature sensor kz
(internal open or short circuit) Resis- a Temperature characteristics of Approx.
tance oil temperature sensor 80 °C
6.5 kz
Approx.
100 °C
3.5 kz
Between P22 (male) (2) and ground Min. 1 Mz
Between CP01 (female) (28) and (46)
Open circuit or short circuit in
2 3.5 to 90
wiring harness Resis- a Resistance accords with value on kz
tance temperature characteristics table in cause
1.
Open circuit in wiring harness 2. Disconnect connectors CP01 and P22, and connect T-adapters to
contact of connector) Between CP01 (female) (28) and P22 (female)
Max. 1 z
Resis- (2)
tance Between CP01 (female) (46) and P22 (female)
(1) Max. 1 z

4 2. Disconnect connectors CP01 and P22, and connect T-adapters to
tance
Hot short circuit in wiring 3. Insert T-adapter between male and female sides of connector CP01
5 harness or connect T-adapter to female side of connector P22.
Between ground and CP01 (28) or P22 Approx. 5
Voltage
(female) (2) V
If no failure is found by above diagnoses, pump controller is defective.
40-596 PC360LC-10
40 Troubleshooting
Circuit diagram related to hydraulic oil temperature sensor
PC360LC-10 40-597
40 Troubleshooting
E-21 Display of hydraulic oil temperature gauge differs from actual oil
temperature (PC400-FGK-400-A-Z0-A)
1) Indication of hydraulic oil temperature gauge is different from actual hydraulic oil
temperature.
Failure
2) Indication of hydraulic oil temperature gauge is different from display of hydraulic oil
temperature monitor.
(Code: 04401)
1 See previous page.
temperature sensor
troubleshooting.
Hydraulic oil Hydraulic oil
temperature 105 °C temperature gauge
level 6
Red
level 5
2 Defective machine monitor temperature 100 °C temperature gauge
Color of level 4
monitor (a) Hydraulic oil
Hydraulic oil
temperature 85 °C temperature gauge Blue
level 3
level 2
temperature 20 °C temperature gauge White
level 1
Hydraulic oil temperature gauge and hydraulic oil temperature monitor
40-598 PC360LC-10
40 Troubleshooting
E-22 Machine monitor does not display partially (PC400-FFC-400-A-Z0-A)
Failure • Machine monitor does not display some items

• LCD panel may have black pixels (that do not light up) or bright pixels (that stay on).
Related information If number of bright and black pixels do not exceed ten, it does not indicate failure or
defect of LCD panel.
a Turn starting switch to ON position and perform troubleshooting.
Defective machine monitor When following switches are operated, if whole LCD panel is lighted up
1
(LCD panel) (whole surface becomes white), LCD panel has no failure.
• Operation of switches: [4] and [F2] (Press simultaneously)
Defective machine monitor
2 defective.
(body)
PC360LC-10 40-599
40 Troubleshooting
E-23 Function switch does not operate (PC400-HBC-400-A-Z0-A)
Failure • Function switch does not work

• Signal of function switch can be checked with monitoring function.
Related information (Code: 04503 Monitor Function Switches)
Machine monitor may be defective. (Since this is an internal defect,
1 Defective machine monitor troubleshooting cannot be performed.)
40-600 PC360LC-10
40 Troubleshooting
E-24 Automatic warm-up system does not work (in cold weather) (PC400-FEN-
400-A-Z0-A)
Failure • Automatic warm-up system does not operate (in cold weather).
• Automatic warm-up function increases engine speed to 1,250 rpm when engine
coolant temperature is below 30 °C .
• With starting switch at ON position or after engine is started, if fuel control dial is kept
at 70% throttle position or higher for 3 seconds, automatic warm-up operation is
Related information
canceled.
• If engine coolant temperature is below 10 °C , turbocharger protection function
works to keep engine speed below 1,000 rpm for up to 20 seconds after engine is
started.
troubleshooting.
a If engine coolant temperature does not match with coolant
temperature gauge level, perform the following troubleshooting
procedures.
• E-18 Engine coolant temperature gauge display does not move
Defective engine coolant Coolant temperature
1 temperature signal system 6 (a: Red)
105 °C
Coolant temperature 5 (a: Red)
Monitoring 102 °C
Coolant code Coolant temperature 4 (a: Blue)
tempera- 04107 100 °C
ture gange Coolant Coolant temperature 3 (a: Blue)
level Tempera- 85 °C
ture Coolant temperature 2 (a: Blue)
60 °C
Coolant temperature 1 (a: White)
30 °C
If no failure is found by checks on cause 1, engine controller is
Engine coolant temperature gauge and engine coolant temperature monitor
PC360LC-10 40-601
40 Troubleshooting
E-25 When auto-decelerator switch is operated, auto-decelerator monitor

does not light up or does not go off (PC400-FFD-400-A-Z0-A)
When auto-deceleration switch is operated, auto-deceleration monitor does not light up
Failure or does not go off.
• Signal of auto-decelerator switch can be checked with monitoring function.
Related information (Code: 04504 Monitor 1st, 2nd row switches)
40-602 PC360LC-10
40 Troubleshooting
E-26 Auto-decelerator is not operated or canceled with lever (PC400-FPM-400-A-Z0-A)
Auto-decelerator is not operated or canceled interlocking with L.H. and R.H. control
Failure
lever.
• Since auto-deceleration set speed is 1,000 rpm, auto-deceleration is not operated or
canceled if engine speed higher than this speed is set by fuel control dial.
Related information • If one-touch power maximizing function does not operate normally, carry out
troubleshooting for "E-38 One-touch power maximizing function does not operate
normally or not displayed on monitor".
a Start engine and perform troubleshooting (with monitoring function).
a If monitoring data show any abnormality, perform troubleshooting
for "E-47 to 55 Monitoring function does not display *** normally".
When lever is
operated: ON
Swing
When lever is in
neutral: OFF
When lever is
operated: ON
Travel
When lever is in
neutral: OFF
When lever is
operated: ON
Monitoring Boom LOWER
code When lever is in
neutral: OFF
01900
When lever is
Pressure operated: ON
Switch 1 Boom RAISE
When lever is in
Defective PPC pressure signal neutral: OFF
1
When lever is
Display of operated: ON
monitoring Arm IN
condition When lever is in
neutral: OFF
When lever is
operated: ON
Arm OUT
When lever is in
neutral: OFF
When lever is
operated: ON
Bucket CURL
When lever is in
Monitoring neutral: OFF
code When lever is
operated: ON
01901 Bucket DUMP
When lever is in
Pressure neutral: OFF
Switch 2 When lever is
operated: ON
Service
When lever is in
neutral: OFF
If no failure is found by above diagnoses, machine monitor may be
If no failure is found by above diagnoses, pump controller may be
3 Defective pump controller defective.
If no failure is found by above diagnoses, engine controller may be
PC360LC-10 40-603
40 Troubleshooting
E-27 When working mode switch is operated, working mode selection

screen is not displayed (PC400-FFE-400-A-Z0-A)
When working mode switch is operated, working mode selection screen is not
Failure displayed.
• Signal of working mode switch can be checked with monitoring function.
40-604 PC360LC-10
40 Troubleshooting
E-28 When working mode is changed, setting of engine and hydraulic

pump is not changed (PC400-FP9-400-A-Z0-A)
Failure When working mode is changed, setting of engine and hydraulic pump is not changed.
Related information

Pump controller may be defective. (Since this is an internal defect,

PC360LC-10 40-605
40 Troubleshooting
E-29 When travel speed switch is operated, travel speed monitor does
not change (PC400-FFF-400-A-Z0-A)
Failure When travel speed switch is operated, travel speed monitor does not change.
• Signal of travel speed selector switch can be checked with monitoring function.
40-606 PC360LC-10
40 Troubleshooting
E-30 When travel speed selection is changed, actual travel speed does
not change (PC400-BQ3-400-A-Z0-A)
Failure When selection of travel speed is changed, actual travel speed does not change.
• When failure due to cause 1 occurs, actual travel speed does not decrease when
travel speed setting is changed to "Lo".
Related information • As T-adapter for pump controller connector is "socket-type box", operating voltage
cannot be measured at pump controller connector.
harness 2. Disconnect connector V04 and connect T-adapters to female side.
circuit)
Voltage Between V04 (female) (2) and ground Max. 4.5 V
If no failure is found by checks for causes 1 and 2, pump controller may
3 Defective pump controller be defective.
Circuit diagram related to travel speed solenoid
PC360LC-10 40-607
40 Troubleshooting
E-31 Alarm buzzer cannot be canceled (PC400-KB3-400-A-Z0-A)
Failure • Alarm buzzer cannot be canceled

• Signal of alarm buzzer cancel switch can be checked with monitoring function.
40-608 PC360LC-10
40 Troubleshooting
E-32 When starting switch is turned OFF, service meter is not

displayed (PC400-FFL-400-A-Z0-A)
Failure • When starting switch is at OFF position, service meter is not displayed.
• While starting switch is at OFF position, if following switches are operated, service
Related information meter is displayed at top center of screen.
Operation of switches: [4] and [1] (Press simultaneously)
If machine monitor displays nothing when the starting switch is turned
ON, the backup power supply system may be defective. Carry out
Defective backup power troubleshooting for the following failures.
1 supply system
• E-5 While starting switch is turned ON, machine monitor displays
nothing
PC360LC-10 40-609
40 Troubleshooting
E-33 Machine monitor cannot be set in service mode (PC400-HB1-400-A-Z0-A)
Failure • Machine monitor cannot be set in service mode

• Following switch operation sets machine monitor in service mode.
Related information Switch operation: [4] and [1] o [2] o [3] (While pressing [4], press [1], [2], and [3] in
order)
40-610 PC360LC-10
40 Troubleshooting
E-34 Any of work equipment, swing and travel does not work (PC300-FT5-400-A-Z0-
A)
Failure All work equipment, swing, and travel do not work

Related information
1 Defective fuse No. 3 of F01 If fuse is blown, circuit may have ground fault. (See cause 7.)
Defective PPC lock switch 2. Disconnect connector S14 and connect T-adapters to female side.
2 3. Operate lock lever and perform troubleshooting.
Resis- Between S14 (male) (1) and (2) FREE Max. 1 z
tance LOCK Min. 1 Mz
Defective PPC lock solenoid 1. Turn starting switch to OFF position.
2. Disconnect connector V01 and connect T-adapters to male side.
3 (open or short circuit in
internal wiring, or ground fault) Resis- Between V01 (male) (1) and (2) 20 to 60 z
2. Disconnect connector D01 and connect T-adapter to male side.
4
(internal ground fault) Between D01 (male) (8) (+) and (4) (-) Continuity
Continuity No
continuity
2. Remove fuse No. 3.
Open or short circuit in wiring 3. Set PPC lock switch to FREE position.
5
harness
Resis- Between fuse F01-3 and ground
20 to 60 z
tance a Resistance of PPC lock solenoid
a If cause 5 is not cause for trouble, this check is not required.
6 Open circuit in wiring harness 3. Disconnect connectors S14 and V01 and connect T-adapters to
each female side.
Between V01 (female) (2) and ground Max. 1 z
Resis- Between V01 (female) (1) and S14 (male) (2)
Max. 1 z
tance
Between fuse F01-3 and S14 (male) (1) Max. 1 z
Ground fault in wiring harness 3. Disconnect connectors S14, D01, and V01 and then connect T-
7
(contact with ground circuit) adapter to male side of S14 or female side of V01.
Between ground and V01 (female) (1) or S14
Resis- (male) (2) Min. 1 Mz
tance
Between S14 (male) (1) and ground Min. 1 Mz
PC360LC-10 40-611
40 Troubleshooting
Circuit diagram related to PPC lock solenoid
40-612 PC360LC-10
40 Troubleshooting
E-35 Any of work equipment, swing and travel cannot be locked (PC300-FT7-400-
A-Z0-A)
Failure Any of work equipment, swing, and travel cannot be locked

Related
information
Defective lock lever 1. Turn starting switch to OFF position.

switch 2. Disconnect connector S14 and connect T-adapters to female side.
1
(internal short circuit) Between S14 (male) (1) Lock lever: LOCK Min. 1 Mz
Resistance and (2)
Lock lever: FREE Max. 1 z
Hot short circuit in wiring 2. Disconnect connector V01 and connect T-adapter to female side.
(contact with 24 V circuit) 4. Turn lock lever to LOCK position.
Voltage Between V01 (female) (2) and (1) Max. 1 V
PC360LC-10 40-613
40 Troubleshooting
Circuit diagram related to PPC lock solenoid
40-614 PC360LC-10
40 Troubleshooting
E-36 Upper structure does not swing while swing brake cancel switch is
set to CANCEL position (PC300-FGM-400-A-Z0-A)
Failure When swing brake cancel switch is set to CANCEL position, upper structure cannot swing.
Related • Signal of swing lock switch can be checked with monitoring function.
information (Pump controller system code: 02200 Switch input 1)
Defective No. 1 in fuse box If fuse is blown out, circuit probably has ground fault. In this case,
1 perform troubleshooting for cause 5 first.
F01
Defective swing brake cancel swing brake cancel
2 switch (internal short circuit) Min. 1 Mz
Resis- Between S25 (male) switch: Normal
tance (13) and (14) swing brake cancel
Max. 1 z
switch: FREE
2. Remove diode array and connect T-adapters to male side.
3
(internal short circuit) Continuity Between D01 (male) (7) (+) and (3) (-) Continuity
No
Continuity Between D01 (male) (3) (+) and (7) (-)
continuity
2. Remove diode array and connect T-adapters to male side.
4
No
continuity
2. Disconnect connector V05 and connect T-adapter to female side.
5 Defective wiring harness a Swing lock switch OFF position.
swing brake cancel
Between V05 (female) switch: FREE 20 to 30 V
Voltage
(1) and (2) swing brake cancel
Max. 1 V
switch: Normal
Open circuit in wiring harness 2. Disconnect connectors V05 and S25, and connect T-adapters to
each female side.
contact of connector) a Swing lock switch OFF position.
Between V05 (female) (1) and S25 (female)
Resis- (14) Max. 1 z
tance
Ground fault in wiring harness 1. Turn starting switch to OFF position.
7 2. Disconnect connectors S25 and V05, and connect T-adapter to
(contact with ground circuit) female side of V05.
Resis- Between V05 (female) (1) and ground
Min. 1 Mz
tance
PC360LC-10 40-615
40 Troubleshooting
Circuit diagram related to swing holding brake
40-616 PC360LC-10
40 Troubleshooting
E-37 Swing brake does not operate while swing brake cancel switch is
set to NORMAL position (PC300-FGN-400-A-Z0-A)
When swing holding brake cancel switch is set to the NORMAL position, swing holding
Failure brake does not operate
Related information
Defective swing brake cancel swing brake cancel
1 switch (internal short circuit) Min. 1 Mz
Resis- Between S25 (male) switch: Normal
tance (13) and (14) swing brake cancel
Max. 1 z
switch: FREE
2. Disconnect connector V05 and connect T-adapter to female side.
Hot short circuit in wiring 3. Turn starting switch to ON position.
2 harness 4. Set swing lock switch to ON position.
a Measure voltage again under swing lock switch OFF position.
Voltage Between V05 (female) (1) and ground Max. 1 V
PC360LC-10 40-617
40 Troubleshooting
40-618 PC360LC-10
40 Troubleshooting
E-38 One-touch power maximizing function does not work properly or

pilot monitor is not displayed (PC300-FGL-400-A-Z0-A)
1) When L.H. knob switch is pressed, one-touch power max. monitor is not displayed.
Failure
2) When L.H. knob switch is pressed, work equipment power is not increased.
• One-touch power max. function does not operate when selected working mode is
not power mode (P) or economy mode (E).
Related information • Signal of L.H. knob switch can be checked with monitoring function.
When L.H. knob switch is pressed, if work equipment power is
increased but one-touch power max. monitor is not displayed on
1 Defective machine monitor machine monitor, machine monitor may be defective. (Since this is an
internal defect, troubleshooting cannot be performed.)
2 Defective fuse No. 8 If fuse is blown, circuit probably has grounding fault. (See Cause 6.)
2. Disconnect connector S11, and connect T-adapters to male side.
Defective left knob switch L.H. knob switch:
3 Min. 1 Mz
(Internal open circuit) Resis- Between S11 (male) Released
tance (1) and (2) L.H. knob switch:
Max. 1 z
Pressed
4
(internal short circuit or ground Resis- Between V08 (male) (1) and (2) 20 to 60 z
fault) tance Between V08 (female) (1) and ground Min. 1 Mz
Open circuit or ground fault in a Ignore displayed failure code.
5 wiring harness
Between CP01 L.H. knob switch:
Max. 1 V
Voltage (female) (42) and Released
ground L.H. knob switch:
20 to 30 V
Pressed
Open circuit in wiring harness 2. Remove fuse F01-8.
6 (wire breakage or defective 3. Disconnect connectors CP01 and S11, and connect T-adapters to
Between F01-8 and S11 (female) (1) Max. 1 z
Resis-
Between S11 (female) (2) and CP01 (female)
tance Max. 1 z
(42)
2. Remove fuse F01-8.
Ground fault in wiring harness 3. Disconnect connectors CP01 and S11, and connect T-adapters to
7
(contact with ground circuit) female side of S11.
Between ground and F01-8 or S11 (female) (1) Min. 1 Mz
Resis-
Between ground and S11 (female) (2) or CP01
tance Min. 1 Mz
(female) (42)
PC360LC-10 40-619
40 Troubleshooting
Circuit diagram related to one-touch power max. switch
40-620 PC360LC-10
40 Troubleshooting
E-39 One-touch power maximizing function cannot be canceled (PC300-FPB-400-

A-Z0-A)
Failure When L.H. knob switch is released, work equipment power is not returned to normal.
Related • Signal of L.H. knob switch can be checked with monitoring function.
information (Code: 02200 Switch input 1)
Voltage Between V08 (female) (1) and (2) Max. 4.5 V
If no failure is found by checks on cause 1, pump controller is defective.
PC360LC-10 40-621
40 Troubleshooting
E-40 Alarm does not sound during travel (PC400-KA4-400-A-Z0-A)
Failure Alarm does not sound during travel.

Related • (2 persons are required for this check.)
information
a Be ready with starting switch OFF, then run engine to perform
troubleshooting.
a If monitoring data is not displayed normally, perform troubleshooting for "E-
54 Travel is not displayed correctly with monitoring function".
Monitoring code Item Correct display
Defective travel signal When one lever is
1
01901 operated: ON
Travel steering
Pressure sensor 2 When lever is in neutral:
OFF
When both levers
01900 operated: ON
Travel
Pressure sensor 1 When lever is in neutral:
OFF
2. Disconnect connector M14, and connect T-adapter to female side.
3. Start engine and operate travel lever.
k Never enter under the machine when operating travel lever.
Defective travel alarm
2
(Internal defect) a When travel lever is set to the travel position, voltage is applied usually to
the travel alarm connector before machine starts moving.
a If voltage is normal but travel alarm does not sound, travel alarm is
defective.
Voltage Between M14 (female) (1) and (2) 20 to 30 V
harness 2. Disconnect connectors M14 and CP02, and connect T-adapters to each
defective contact of Between CP02 (female) (107) and M14 (female) (1) Max. 1 z
Between M14 (female) (2) and ground Max. 1 z
harness 2. Disconnect connectors CP02 and M14, and connect T-adapter to either
4 female side.
Between CP02 (female) (107) and ground, or M14
circuit) Resistance (female) (1) and ground Min. 1 Mz
40-622 PC360LC-10
40 Troubleshooting
PC360LC-10 40-623
40 Troubleshooting
E-41 Alarm does not stop sounding while machine is stopped (PC400-KB5-400-A-
Z0-A)
Failure Alarm does not stop sounding while machine is stopped.

Related information
harness 2. Disconnect connector M14 and connect T-adapters to female side.
circuit)
Voltage Between M14 (female) (1) and ground Max. 1 V
40-624 PC360LC-10
40 Troubleshooting
E-42 Horn does not sound (PC300-KA2-400-A-Z0-A)
Failure The horn does not sound

Related
information
If fuse F01(5) is broken, circuit probably has ground fault. In this case,
1 Defective fuse F01-5 perform troubleshooting for cause 7 first.
Defective horn relay 2. Replace horn relay (connector: R08) with another relay.
2 (internal open circuit or short 3. Turn starting switch to ON position.
circuit) 4. Press right knob switch.
If horn sounds, original horn relay is defective.
Defective horn switch 1. Turn starting switch to OFF position.

2. Disconnect connector S10, and connect T-adapter to male side.
3 (internal open circuit or short
circuit) Resis- Between S10 (male) Switch: OFF Min. 1 Mz
tance (1) and (2) Switch: ON Max. 1 z
Defective high-tone horn
2. Disconnect connectors M07 and M08, and connect T-adapters to
(M07) or low-tone horn (M08)
4 each male side.
(open or short circuit in
Between M07 (male) (1) and (2) Continuity
internal wiring) Continuity
Between M08 (male) (1) and (2) Continuity
2.Disconnect connector R08 and connect T-adapters to female side.
3.Turn starting switch to ON position.
5 Defective wiring harness 4.Press right knob switch.
Between R08 (female) (1) and (2) 20 to 30 V
Voltage
Between R08 (female) (3) and (2) 20 to 30 V
2. Disconnect connector R08 and connect T-adapters to female side.
Between R08 (female) (1) and ground Continuity
Continuity
Between R08 (female) (5) and ground Continuity
a If no failure is found by above checks, this check is not required.
6 (wire breakage or defective 2. Remove fuse F01-5.
contact of connector) 3. Disconnect connectors R08 and S10, and connect T-adapters to
each female side.
Between F01-5 and S10 (female) (1) Max. 1 z
Resis- Between S10 (female) (2) and R08 (female) (1) Max. 1 z
tance Between R08 (female) (2) and ground Max. 1 z
Between R08 (female) (3) and F01(5) Max. 1 z
2. Remove fuse F01-5.
Ground fault in wiring harness 3. Disconnect connectors R08, M07, and M08, and connect T-
7
(contact with ground circuit) adapters to female side of R08.
Between R08 (female) (1) and ground Min. 1 Mz
Resis- Between R08 (female) (3) and ground
Min. 1 Mz
tance
Between R08 (female) (5) and ground Min. 1 Mz
Defective horn
8 If no failure is found by above checks, horn may be defective.
(internal defect)
PC360LC-10 40-625
40 Troubleshooting
Circuit diagram related to horn
40-626 PC360LC-10
40 Troubleshooting
E-43 Horn does not stop sounding (PC400-KB2-400-A-Z0-A)
Failure Horn does not stop sounding

Related information
Defective horn relay (R08) 1. Turn starting switch to OFF position.
2. Remove horn relay (connector R08).
1 tor (internal open or short 3. Turn starting switch to ON position.
circuit)
If horn stops sounding, original horn relay is defective.
Hot short circuit in wiring 2. Disconnect connectors M07 and M08, and connect T-adapters to
circuit)
Between M07 (female) (2) and (1) Max. 1 V
Voltage
Between M08 (female) (2) and (1) Max. 1 V
Circuit diagram related to horn
PC360LC-10 40-627
40 Troubleshooting
E-44 When wiper switch is operated, wiper monitor does not light up or
go off (PC400-FG4-400-A-Z0-A)
Failure When wiper switch is operated, wiper monitor does not light up or go off.
• Signal of wiper switch can be checked with monitoring function.
40-628 PC360LC-10
40 Troubleshooting
E-45 Wiper does not operate when wiper switch is operated (PC300-FG0-400-A-Z0-A)
Failure When wiper switch is operated, windshield wiper does not operate
• Signal of window rear limit switch can be checked with monitoring function.
Related (Code: 02204 Switch input 5)
information • Wiper motor is checked and its failure is expressed in failure code [DY20KA],
[DY20MA], [DY2DKB], or [DY2EKB].
2. Disconnect connector W03.
Defective window rear
limit switch (Internal short Front window: when set
1 Min. 1 Mz
circuit) Between W03 (male) (1) in position
Resistance and (2)
Front window: when
pulled up Max. 1 z

2 2. Disconnect connector M05 and connect T-adapters to female side.
Continuity Between M05 (female) (1) and (3) Continuity
a Wiper motor system
See troubleshooting for failure codes [DY20KA], [DY20MA], [DY2DKB],
and [DY2EKB].
harness
3 (wire breakage or a Wiper rear limit switch system
defective contact of 1. Turn starting switch to OFF position.
connector) 2. Disconnect connector CP01 and connect T-adapter to female side.
3. Pull up front window.
Resistance Between CP01 (female) (76) and ground Max. 1 z
harness 2. Disconnect connector CP01 and connect T-adapter to female side.
4 3. Set front window in position.
circuit) Resistance Between CP01 (female) (76) and ground Min. 1 Mz
PC360LC-10 40-629
40 Troubleshooting
Circuit diagram related to wiper motor
40-630 PC360LC-10
40 Troubleshooting
E-46 When window washer switch is operated, window washer does not
operate (PC400-FH0-400-A-Z0-A)
Failure When window washer switch is operated, window washer does not operate.
• Signal of window washer switch can be checked with monitoring function.
(Code: 04504 Monitor 1st, 2nd row switches)
Related information • Window washer is checked and its failure is expressed in failure codes [DY2CKA] or
[DY2CKB].
PC360LC-10 40-631
40 Troubleshooting
E-47 Boom LOWER indicator is not displayed properly with monitoring

function (PC400-FFR-400-A-Z0-A)
Failure "Boom LOWER" operation signal is not displayed properly on monitoring screen.
Related information • Monitoring code: 01900 Pressure Sensor 1
Defective boom LOWER PPC
oil pressure sensor system
1 Perform troubleshooting for failure code [DHS9MA].
circuit)
40-632 PC360LC-10
40 Troubleshooting
E-48 Arm OUT indicator is not displayed properly with monitoring

function (PC400-FFS-400-A-Z0-A)
Failure "Arm OUT" operation signal is not displayed properly on monitoring screen.
Defective arm OUT PPC oil
1 Perform troubleshooting for failure code [DHSCMA].
circuit)
PC360LC-10 40-633
40 Troubleshooting
E-49 Arm IN indicator is not displayed properly with monitoring

function (PC400-FFN-400-A-Z0-A)
Failure "Arm IN" operation signal is not displayed properly on monitoring sceen.
Defective arm IN PPC
1 pressure sensor system Perform troubleshooting for failure code [DHS3MA].
(internal open or short circuit)
40-634 PC360LC-10
40 Troubleshooting
E-50 Boom RAISE indicator is not displayed properly with monitoring

function (PC400-FFM-400-A-Z0-A)
Failure "Boom RAISE" operation signal is not displayed properly on monitoring screen.
Defective boom RAISE PPC
1 pressure sensor system Perform troubleshooting for failure code [DHS8MA].
(internal open or short circuit)
PC360LC-10 40-635
40 Troubleshooting
E-51 Bucket CURL indicator is not displayed properly with monitoring

function (PC400-FFP-400-A-Z0-A)
Failure "Bucket CURL" operation signal is not displayed properly on monitoring screen.
Defective bucket CURL PPC
1 Perform troubleshooting for failure code [DHS4MA].
40-636 PC360LC-10
40 Troubleshooting
E-52 Bucket DUMP indicator is not displayed properly with monitoring

function (PC400-FFQ-400-A-Z0-A)
Failure "Bucket DUMP" operation signal is not displayed properly on monitoring screen.
Defective bucket DUMP PPC
1 Perform troubleshooting for failure code [DHSDMA].
PC360LC-10 40-637
40 Troubleshooting
E-53 Swing indication is not displayed properly with monitoring

function (PC300-FFT-400-A-Z0-A)
Failure "Swing" operation signal is not displayed properly on monitoring screen.
Related information • Monitoring code: 01900 Pressure sensor 1
Defective swing PPC pressure
sensor system
1 Perform troubleshooting for failure codes [DHSAMA] and [DHSBMA].
circuit)
40-638 PC360LC-10
40 Troubleshooting
E-54 Travel indication is not displayed properly with monitoring

function (PC300-FFU-400-A-Z0-A)
Failure "Travel" operation signal is not displayed properly on monitoring screen.
Related information • Monitoring code: 01900 Pressure sensor 1
Defective travel PPC oil
pressure sensor system Perform troubleshooting for failure codes [DHSFMA], [DHSGMA],
1 [DHSHMA] and [DHSJMA].
circuit)
PC360LC-10 40-639
40 Troubleshooting
E-55 Service indication is not displayed properly with monitoring

function (PC300-FFW-400-A-Z0-A)
Failure "Attachment" operation signal is not displayed properly on monitoring screen.
• Monitoring code: 01901 Pressure switch 2
• For safety, use "short connector" 799-601-7230 for 2-pin X connector in
Related information troubleshooting for cause 1 and 2.
k Do not check pressure switch connector while engine is running.
A. If "Service" operation signal displayed on monitoring screen is not
"ON" when engine is started and attachment control pedal is
depressed at front end
2. Disconnect connector P14 and connect "short connector" to female
side.
a After finishing troubleshooting, return connectors as they were.
Defective PPC pressure • If "Service" operation signal displayed on monitoring screen
1 switch (P14) for front end of changes to "ON", front service PPC pressure switch (P14) is
attachment control pedal defective (Note 1).
B. If "Service" operation signal displayed on monitoring screen is ON"
when starting switch is turned to ON position
• If "Service" operation signal displayed on monitoring screen
changes to "OFF", front service PPC pressure switch (P14) is
defective (Note 2).
A. If "Service" operation signal displayed on monitoring screen is not
"ON" when engine is started and attachment control pedal is
depressed at rear end
2. Disconnect connector P15 and connect "short connector" to female
side.
a After finishing troubleshooting, return connectors as they were.
Defective PPC pressure • If "Service" operation signal displayed on monitoring screen
2 switch (P15) for rear end of changes to "ON", rear service PPC pressure switch (P15) is
attachment control pedal defective (Note 1).
B. If "Service" operation signal displayed on monitoring screen is ON"
when starting switch is turned to ON position
• If "Service" operation signal displayed on monitoring screen
changes to "OFF", rear service PPC pressure switch (P15) is
defective (Note 2).
2.Insert T-adapters into P13.
3.Engine start
4.Operate attachment control pedal, and perform troubleshooting.
Defective wiring harness or
3 pump controller Between P13 (1) and attachment control Approx. 7
(2) pedal: Neutral V
Voltage attachment control
Between P13 (1) and
pedal: front end or rear Max. 1 V
(2)
end depressed
40-640 PC360LC-10
40 Troubleshooting

2. Disconnect connectors CP01, P14, and P15, and connect T-
adapters to each female side.
(1) Max. 1 z
contact of connector) Resis- Between CP01 (female) (35) and P15 (female) Max. 1 z
tance (1)
Ground fault in wiring harness 2. Disconnect connectors CP01, P14, and P15, and connect T-
5 adapters to either female side.
Resis- Between ground and CP01 (female) (35), P14
(female) (1), or P15 (female ) (1) Min. 1 Mz
tance
2. Disconnect connectors P14 and P15, and connect T-adapters to
either female side.
Between P14 (female) (1) and ground, or Approx. 7
Voltage
between P15 (female) (1) and ground V
Note 1: If voltage between CP01 (35) and ground is below 1 V but monitoring indication for "Service" is "OFF",
pump controller is defective.
Note 2: If voltage between CP01 (35) and ground is approx. 7 V but monitoring indication for "Service" is "ON",
pump controller is defective.
Circuit diagram related to service pressure switch
PC360LC-10 40-641
40 Troubleshooting
E-56 Attachment circuit is not switched (PC300-HBD-400-A-Z0-A)

• Attachment circuit cannot be changed
Failure 1) When working mode P or E is selected, crusher circuit (two-way circuit) is not selected.
2) When working mode B is selected, breaker circuit (one-way circuit) is not selected.
Related • Failures (open circuit/short circuit) in attachment oil return selector solenoid are indicated
information by failure codes [DWA2KA] and [DWA2KB].
Defective attachment oil 2. Disconnect connector V07, and connect T-adapters to male side.
1 return selector solenoid
(internal short circuit) Resis- Between V07 (male) (1) and (2) 20 to 60 z
Voltage Between V07 (female) (1) and ground Max. 4.5V
Circuit diagram related to attachment oil return selector solenoid
40-642 PC360LC-10
40 Troubleshooting
E-57 KOMTRAX system does not operate properly (PC300-F50-400-A-Z0-A)
Failure • KOMTRAX system does not operate properly.

• Perform following troubleshooting if administrator of KOMTRAX system requests to
Related check whether failure is occurring in system on machine.
information • Even when KOMTRAX system is defective, no problem appears on machine.
• Check all of results of troubleshooting on service menu display of machine monitor.
2. Display “Terminal status” screen.
1 Defective communication 1
Monitoring Check item:
To be completed
display Station set-up check
2. Display “GPS & Communication Status” screen.
N ###.##.## (Latitude)
Monitoring Check item:
2 Defective positioning by GPS E ###.##.## (Longitude)
display Positioning
In positioning
If latitude and longitude are not displayed within 5 minutes with
machine stayed outdoor where opens clearly for sky, contact
KOMTRAX service hot line.
Monitoring Check item: Satellite in View or No Satellite in
Defective communication display Communication View
3
environment If Communication Status does never display “Satellite in View” within
15 minutes with machine stayed outdoor where opens clearly for sky,
check if connector of TC330 or antenna on top of cab are properly
connected.
4 Defective communication 2 Check item:
Monitoring
Number of message 0 to 60 (normally 0)
display
not yet sent
a Select “Terminal Status” from “12 Display of a Select “GPS & Communication Status” from “12
KOMTRAX setting” in service menu of machine Display of KOMTRAX setting” in service menu of
monitor. machine monitor.
PC360LC-10 40-643
40 Troubleshooting
E-58 Machine push-up function is not canceled (PC300-FTH-400-A-Z0-A)
Machine push-up function cannot be canceled

Failure
• Machine push-up solenoid is not energized.
Related • Normally, machine push-up solenoid is energized when machine push-up switch is set
information to low-pressure setting.
1 Blown fuse No.2 If fuse is blown, circuit may have ground fault. (See cause 7.)
Defective machine push- 2. Disconnect S05 and connect T-adapter to male side.
up 3. Turn switch to OFF and ON position and perform troubleshooting.
2 High pressure (Switch
switch (open circuit in Min. 1 Mz
Between S05 (male) (5) OFF)
internal wiring) Resistance and (6) Low pressure (Switch
ON) Max. 1 z
Defective machine push- 1. Turn starting switch to OFF position.
up 2. Remove fuse No. 2.
3
(open or short circuit in Between V06 (male) (2) and (1) 20 to 60 z
internal wiring, or ground Resistance
fault) Between V06 (male) (1) and ground Min. 1 Mz
2. Remove diode array D03 and connect T-adapter.
Defective diode array
4 D03 a Check by using multimeter in diode range.
No
continuity
Open or short circuit in 3. Turn machine push-up switch to lower pressure (ON) position and
5 wiring harness perform troubleshooting.
a To measure machine push-up solenoid coil resistance
Resistance Between F01-2 and ground 20 to 60 z

harness 2. Disconnect connectors S05, V06, and D03, and connect T-adapters to
female side of V06 and to female side of S05.
6 (wire breakage or Between F01-2 outlet and S05 (male) (5) Max. 1 z
connector) Resistance Between S05 (female) (6) and V06 (female) (1) Max. 1 z
Ground fault in wiring 2.Remove fuse No. 2.
harness 3.Disconnect connectors S05, V06, and D03, and connect T-adapters to
7 female side of S05, V06, or D03.
circuit) Between ground and F01-2 outlet or S05 (female)
(5) Min. 1 Mz
Resistance
Between ground and S05 (male) (6), V06 (female)
(1), or D03 (female) (2) Min. 1 Mz
40-644 PC360LC-10
40 Troubleshooting
Circuit diagram related to machine push-up switch
PC360LC-10 40-645
40 Troubleshooting
E-59 Machine push-up function does not work (PC300-FTG-400-A-Z0-A)
Machine push-up function does not operate

Failure
• Machine push-up solenoid remains energized.
• Normally, machine push-up solenoid is de-energized when machine push-up switch
Related information is set to high-pressure setting.
2. Disconnect S05 and connect T-adapter to male side.
3. Turn machine push-up switch to OFF and ON positions and perform
Defective machine push-up troubleshooting.
1 switch (short circuit in internal
wiring) High pressure (Switch
OFF) Min. 1 Mz
Resis- Between S05 (male)
tance (5) and (6) Low pressure (Switch
ON) Max. 1 z

2. Disconnect connectors D03 and V06, and connect T-adapter to
Hot short circuit in wiring either female side.
2 harness (contact with 24 V 3. Turn starting switch to ON position.
circuit) a Machine push-up switch OFF (High pressure)
Between ground and V06 (female) (1) or D03
Voltage Max. 1 V
(female) (1)
Circuit diagram related to machine push-up switch
40-646 PC360LC-10
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)
Troubleshooting of hydraulic and mechanical system (H-mode) (ALL-

3840-001-A-02-A)
Information described in troubleshooting table (H-mode) (ALL-5170-010-A-00-A)
(Rev. 2011/03)
Failure Failure symptom that appears on machine
Related Information on occurred failure or troubleshooting
information
1
2 Probable cause of failure <Contents of description>
(Each number is serial
3 number, not priority • Criteria to determine probable causes
4 sequence.) • Remarks for determination of probable cause
5
PC360LC-10 40-647
40 Troubleshooting
mode)
List of Failure Mode and Cause (PC300-5340-40D-A-00-A)

Component causing failure Tank Hydraulic pump
Piston pump (work equipment, swing, travel)
Troubleshooting code
Engine system
PC-EPC valve
LS-EPC valve
Hydraulic oil
Servo piston
PC valve
LS valve
Strainer
Damper
Cap
z
Failure mode
All of work equipment, swing and travel operation lacks speed or power. q q q q q q q q q H-1
All work equipment, swing
Engine speed lowers significantly or engine stalls. q q q q q q q q H-2

and travel systems
Any of work equipment, swing and travel does not work. q q q H-3
Unusual noise is heard from around hydraulic pump. q q q q H-4
Fine control performance or response is poor. q q q H-5
Speed or power of boom is low. H-6
Speed or power of arm is low. H-7
Speed or power of bucket is low. H-8
Work equipment does not move in single operation. H-9
Hydraulic drift of boom is large.

Work equipment
H-10
Hydraulic drift of arm is large. H-11
Hydraulic drift of bucket is large. H-12
Time lag of work equipment is large. q H-13
Other wok equipment moves when one of work equipment is relieved. H-14
One-touch power maximizing function does not work.. H-15
Machine push-up function does not operate. H-16
Work equipment loaded more is slower during combined operation. H-17

and boom
Swing
In combined operations of swing and boom RAISE, boom rising speed is low. H-18
and travel
Swing
Travel speed drops largely in combined operation of swing and travel. H-19
Machine deviates during travel. q H-20
Travel speed is low. q H-21

Travel
Machine is not steered well or steering power is low. H-22
Travel speed does not change or travel speed is too low or high. q H-23
H-24
One of tracks does not run..
40-648 PC360LC-10
40 Troubleshooting
mode)
Component causing failure Tank Hydraulic pump
Piston pump (work equipment, swing, travel)
Engine system
PC-EPC valve
LS-EPC valve
Hydraulic oil
Servo piston
PC valve
LS valve
Strainer
Damper
Cap
z
Failure mode
Upper structure swings neither to the right nor left. H-25
Upper structure does not swing in only one direction. H-26
Swing acceleration or swing speed is low in both directions (right and left). H-27
H-28
direction.
Upper structure overruns remarkably when it stops swinging in both
H-29
Swing
directions (right and left).

H-30
direction.
Large shock noise is made when upper structure stops swinging. H-31
Large unusual noise is heard when upper structure stops swinging. H-32
When swing holding brake is applied, hydraulic drift of swing is large. H-33
When swing holding brake is released, hydraulic drift of swing is large. H-34
When additional attachment is installed, attachment circuit is not switched.

Attachment
H-35
Oil flow in attachment circuit cannot be changed. H-36
PC360LC-10 40-649
40 Troubleshooting
mode)
Component causing failure Control valve
Merge-divider main EPC valve

Pressure compensation valve
Self-pressure reducing valve
Merge-divider LS-EPC valve
Service valve (safety valve)

Swing LS separation valve
Arm lock valve (optional)
Merge-divider main valve
Boom regeneration valve
Arm regeneration valve

Merge-divider LS valve
Arm quick return valve
Travel junction valve

Back pressure valve
Main relief valve
Boom lock valve
LS shuttle valve
LS line orifice
Suction valve
Unload valve
Safety valve
Spool
Failure mode
All of work equipment, swing and travel operation lacks speed or power. q q q H-1
Engine speed lowers significantly or engine stalls. H-2

and travel systems
Any of work equipment, swing and travel does not work. q H-3
Unusual noise is heard from around hydraulic pump. H-4
Fine control performance or response is poor. q H-5
Speed or power of boom is low. q q q q q q q q q q q H-6
Speed or power of arm is low. q q q q q q q q q q q q H-7
Speed or power of bucket is low. q q q q q q q q q H-8
Work equipment does not move in single operation. q H-9

Work equipment
q q q H-10
Hydraulic drift of arm is large. q q q q H-11
Hydraulic drift of bucket is large. q q q H-12
Time lag of work equipment is large. q q q q H-13
Other wok equipment moves when one of work equipment is relieved. q H-14
One-touch power maximizing function does not work.. q H-15
Machine push-up function does not operate. q H-16
Work equipment loaded more is slower during combined operation. q H-17

and boom
Swing
In combined operations of swing and boom RAISE, boom rising speed is low. q H-18
and travel
Swing
Travel speed drops largely in combined operation of swing and travel. q H-19
Machine deviates during travel. q q q q q H-20
Travel speed is low. q q q q q H-21

Travel
Machine is not steered well or steering power is low. q q q q q q q q q H-22
Travel speed does not change or travel speed is too low or high. H-23
One of tracks does not run.. q H-24
Upper structure swings neither to the right nor left. q H-25
Upper structure does not swing in only one direction. q H-26
Swing acceleration or swing speed is low in both directions (right and left). q q H-27
q q H-28
direction.
H-29
Swing

q H-30
direction.
Large shock is made when upper structure stops swinging. H-31
Large unusual noise is heard when upper structure stops swinging. q H-32
When swing holding brake is released, hydraulic drift of swing is large. q q H-34

Attachment
q H-35
40-650 PC360LC-10
40 Troubleshooting
mode)
Component causing failure Solenoid valve Swing motor
ATT oil flow adjustment EPC valve
PPC valve (travel control lever)
Travel speed selector solenoid

Work equipment lock solenoid
Swing PPC slow return valve
Swing 2-stage relief solenoid

Swing holding brake solenoid
ATT return selector solenoid
Machine push-up solenoid

Travel junction solenoid
PPC valve (R.H. lever)
PPC valve (L.H. lever)
2-stage relief solenoid

PPC valve (service)
Shockless valve
Parking brake
Suction valve
Piston motor
Safety valve
Check valve
Failure mode
All of work equipment, swing and travel operation lacks speed or power. H-1

and travel systems
Any of work equipment, swing and travel does not work. q H-3
Fine control performance or response is poor. H-5
Speed or power of boom is low. q q H-6
Speed or power of arm is low. q H-7
Speed or power of bucket is low. q H-8
Work equipment does not move in single operation. q q H-9

Work equipment
H-10
Hydraulic drift of arm is large. H-11
Hydraulic drift of bucket is large. H-12
Time lag of work equipment is large. H-13
One-touch power maximizing function does not work.. q H-15
Machine push-up function does not operate. q H-16

and boom
Swing
and travel
Swing
Machine deviates during travel. q q H-20
Travel speed is low. q H-21

Travel
Machine is not steered well or steering power is low. q q H-22
One of tracks does not run.. H-24
Upper structure swings neither to the right nor left. q q q q q H-25
Upper structure does not swing in only one direction. q q q H-26
Swing acceleration or swing speed is low in both directions (right and left). q q q H-27
q q q H-28
direction.
q q H-29
Swing

q q q q H-30
direction.
Large shock is made when upper structure stops swinging. q q q H-31
Large unusual noise is heard when upper structure stops swinging. q q H-32
When the swing holding brake is applied, hydraulic drift of swing is large. q q H-33
When swing holding brake is released, hydraulic drift of swing is large.. q q q q H-34

Attachment
q H-35
Oil flow in attachment circuit cannot be changed. q q H-36
PC360LC-10 40-651
40 Troubleshooting
mode)
Component causing failure Travel motor
Counterbalance valve
Center swivel joint
Hydraulic cylinder
Swing machinery
Parking brake
Piston motor
Safety valve
Check valve
Final drive
Failure mode
All of work equipment, swing and travel operation lacks speed or power. H-1

and travel systems
Any of work equipment, swing and travel does not work. H-3
Fine control performance or response is poor. H-5
Speed or power of boom is low. q H-6
Speed or power of arm is low. q H-7
Speed or power of bucket is low. q H-8
Work equipment does not move in single operation. H-9

Work equipment
q H-10
Hydraulic drift of arm is large. q H-11
Hydraulic drift of bucket is large. q H-12
Time lag of work equipment is large. H-13
One-touch power maximizing function does not work.. H-15
Machine push-up function does not operate. H-16

and boom
Swing
and travel
Swing
Machine deviates during travel. q q q q q H-20
Travel speed is low. q q H-21

Travel
Machine is not steered well or steering power is low. q q q q H-22
One of tracks does not run.. q q q q q H-24
Upper structure swings neither to the right nor left. q H-25
Upper structure does not swing in only one direction. H-26
Swing acceleration or swing speed is low in both directions (right and left). q H-27
H-28
direction.
H-29
Swing

H-30
direction.
Large shock is made when upper structure stops swinging. H-31
Large unusual noise is heard when upper structure stops swinging. q H-32
When swing holding brake is released, hydraulic drift of swing is large.. H-34

Attachment
H-35
40-652 PC360LC-10
40 Troubleshooting
mode)
H-1 All of work equipment, swing and travel operation lacks speed or
power (PC300-A8A-400-A-Z0-A)
Failure • All of work equipment, swing and travel operation lacks speed or power.
• Perform all troubleshooting with working mode set in P mode.
• If failure codes are displayed, perform troubleshooting for them first. (DKR0MA, DKR1MA,
DXA8KA, DXA8KB, DXA9KA, DXA9KB, DXE0KA, DXE0KB)
• As for speed other than swing speed, check whether normal speed is obtained with swing
Related lock switch turned ON.
information If normal speed is obtained, perform troubleshooting on causes 1 and 2 to check pump
swash plate sensor for malfunction.
If normal speed is not obtained, perform troubleshooting on cause 3 and after.
• F pump pressure and R pump can be checked with monitoring function. (Code: F pump
pressure 01100, R pump pressure 01101)
a Be ready with engine stopped, then perform troubleshooting with engine
running at full speed.
Malfunction of pump swash All levers in NEUTRAL 1.560 ± 0.63 V
1 plate sensor (front)
Sensor output L.H. track only: Running idle off
voltage ground 3.632 ± 0.63 V
Swing lock switch: ON
2 plate sensor (rear)
Sensor output R.H. track only: Running idle off
Malfunction of unload valve running at full speed.
3 (front)
3.9 ± 1.0 MPa
Unload pressure All levers in NEUTRAL
{40 ± 10 kg/cm2}
Malfunction of unload valve running at full speed.
4 (rear)
3.9 ± 1.0 MPa
Unload pressure All levers in NEUTRAL
{40 ± 10 kg/cm2}
Malfunction of main relief 33.15 to 36.77
5 valve (front)
Main relief MPa
Boom RAISE hydraulic relief
pressure {338 to 375 kg/
cm2}
Malfunction of main relief 33.15 to 36.77
6 valve (rear)
Main relief MPa
Arm IN hydraulic relief
pressure {338 to 375 kg/
cm2}
If normal oil pressure is not obtained after adjustment, check main relief
Malfunction of main relief
7 valve (front) valve for malfunction (setting of spring) and internal failure (defective valve
seat).
8 valve (rear) valve for malfunction (setting of spring) and internal failure (defective valve
seat).
PC360LC-10 40-653
40 Troubleshooting
mode)

Control circuit 2.84 to 3.43 MPa
Malfunction of self- All levers in NEUTRAL
9 pressure reducing valve source pressure {29 to 35 kg/cm2}
a Since relief valve of self-pressure reducing valve is not adjustable,
replace self-pressure reducing valve assembly if normal pressure is not
obtained.
running at low idle and at high idle.
Approx. 1.7 MPa
Engine at low idle and all levers in {Approx. 18 kg/
Malfunction of PC-EPC NEUTRAL
10 valve (front) PC-EPC valve cm2}
output pressure Approx. 0.2 MPa
Engine at high idle and all levers in {Approx. 2 kg/
NEUTRAL cm2}
Replace PC-EPC valve if any failure is found.
running at low idle and at high idle.
Malfunction of PC-EPC Engine at low idle and all levers in 2.9 MPa {30 kg/
11 valve (rear) PC-EPC valve NEUTRAL cm2}
output pressure Engine at high idle and all levers in 0.98 MPa {10 kg/
NEUTRAL cm2}
Replace PC-EPC valve if any failure is found.
Measurement condition
measured
Pump delivery Swing lock switch: ON
Defective adjustment of PC 1
12 valve (front) pressure Boom RAISE hydraulic relief
PC valve output Swing lock switch: ON Approx. 0.6
pressure Boom RAISE hydraulic relief (Approx. 3/5)
If normal pressure is not obtained after adjustment, PC valve may
malfunction (setting of spring) or have internal failure (locked or trapped PC
spool). Check PC valve.
measured
Defective adjustment of PC Pump delivery 1
13 valve (rear) pressure Arm IN hydraulic relief
pressure Arm IN hydraulic relief (Approx. 3/5)
If normal pressure is not obtained after adjustment, PC valve may
malfunction (setting of spring) or have internal failure (locked or trapped PC
spool). Check PC valve.
Approx. 1.5 MPa
Malfunction of LS-EPC Travel control Travel speed: Lo {Approx. 15 kg/
14 lever: NEUTRAL
valve LS-EPC valve cm2}
output pressure Travel control
lever: Finely Travel speed: Hi 0 MPa {0 kg/cm2}
moved
40-654 PC360LC-10
40 Troubleshooting
mode)

Lever position and oil pressure ratio
L.H. track:
Running idle off
Oil pressure to be ground in Hi
Defective adjustment of LS measured All levers in NEUTRAL
15 valve (front) speed setting
Lever moved
halfway
Pump delivery Almost same as LS valve output
pressure pressure 1
LS valve output Almost same as pump delivery Approx. 0.6
pressure pressure (Approx. 3/5)
R.H. track:
Running idle off
16 valve (rear) speed setting
Lever moved
halfway
pressure pressure 1
LS valve out put Almost same as pump delivery Approx. 0.6
If normal oil pressure is not obtained after adjustment, check LS valve for
Malfunction of LS valve
17 (front) malfunction (setting of spring) and internal failure (locked or trapped LS
spool).
Malfunction of LS valve malfunction (setting of spring) and internal failure (locked or trapped LS
18 (rear)
spool).
PC360LC-10 40-655
40 Troubleshooting
mode)

If sensor output voltage is normal in checks on causes 1 and 2, determine
Malfunction of servo piston that servo piston is normal.
19 or PC valve (*)
Check orifices and filters in pump servo devices for clogging.
If no failure is found by above checks, piston pump may have degraded
20 Malfunction of piston pump performance, malfunction, or have internal failure.
Check hydraulic tank strainer and return filter element for metal particles.
(*) Since PC valve is built in servo piston, servo piston assembly must be replaced if PC valve is defective.
40-656 PC360LC-10
40 Troubleshooting
mode)
H-2 Engine speed lowers significantly or engine stalls (PC300-FPN-400-A-Z0-A)
Failure • Engine speed lowers significantly or engine stalls.

• If failure codes are displayed, perform troubleshooting for them first. (DKR0MA,
DKR1MA, DXA8KA, DXA8KB, DXA9KA, DXA9KB, DXE0KA, DXE0KB)
• As for speed other than swing speed, check whether normal speed is obtained with swing
Related lock switch turned ON.
information If normal speed is obtained, perform troubleshooting on causes 1 and 2 to check pump
swash plate sensor for malfunction.
If normal speed is not obtained, perform troubleshooting on cause 3 and after.
a Be ready with engine stopped, then perform troubleshooting with
engine running at full speed.
1 plate sensor (front) Sensor output L.H. track only: Running idle
voltage off ground 3.632 ± 0.63 V
2 plate sensor (rear) Sensor output R.H. track only: Running idle
voltage off ground 3.632 ± 0.63 V
Malfunction of main relief engine running at full speed.
3 valve (front) 33.15 to 36.77 MPa
Main relief pressure Boom RAISE hydraulic relief
{338 to 375 kg/cm2}
Malfunction of main relief engine running at full speed.
4 valve (rear) 33.15 to 36.77 MPa
Main relief pressure Arm IN hydraulic relief
{338 to 375 kg/cm2}
5 valve for malfunction (setting of spring) and internal failure (defective
valve (front)
valve seat).
6 valve for malfunction (setting of spring) and internal failure (defective
valve (rear)
valve seat).
Malfunction of PC-EPC valve Approx. 1.7 MPa
7 Engine at low idle and all {Approx. 18 kg/
(front) PC-EPC valve levers in NEUTRAL cm2}
output pressure
Engine at high idle and all Approx. 0.2 MPa
levers in NEUTRAL {Approx. 2 kg/cm2}
Malfunction of PC-EPC valve Engine at low idle and all 2.9 MPa {30 kg/
8 (rear) PC-EPC valve levers in NEUTRAL cm2}
output pressure Engine at high idle and all 0.98 MPa {10 kg/
levers in NEUTRAL cm2}
PC360LC-10 40-657
40 Troubleshooting
mode)

Defective adjustment of PC measured
9 valve (front) Swing lock switch: ON
Pump delivery
pressure 1
Boom RAISE hydraulic relief
pressure Boom RAISE hydraulic relief (Approx. 3/5)

Defective adjustment of PC measured
10 valve (rear) Swing lock switch: ON
Pump delivery
pressure 1
Arm IN hydraulic relief
pressure Arm IN hydraulic relief (Approx. 3/5)
If normal oil pressure is not obtained after adjustment, check PC valve
11 Malfunction of PC valve (front) for malfunction (setting of spring) and internal failure (locked or trapped
PC spool).
If normal oil pressure is not obtained after adjustment, check PC valve
12 Malfunction of PC valve (rear) for malfunction (setting of spring) and internal failure (locked or trapped
PC spool).
Travel Approx. 1.5 MPa
Travel control lever: {Approx. 15 kg/
13 Malfunction of LS-EPC valve speed:
LS-EPC valve NEUTRAL cm2}
Lo
output pressure
Travel control lever: Travel
speed: 0 MPa {0 kg/cm2}
Finely moved
Hi
Track running idle
Oil pressure to be off ground
14 valve (front) (Lever moved
halfway)
Pump delivery Almost same as LS valve
pressure pressure 1
Pump delivery pressure is
LS valve output Approx. 0.6
almost same as LS valve
pressure (Approx. 3/5)
pressure.
Track running idle
Oil pressure to be off ground
measured All levers in NEUTRAL
Defective adjustment of LS (Lever moved
15 valve (rear) halfway)
Pump delivery
almost same as LS valve 1
pressure
pressure.
LS valve output Approx. 0.6
almost same as LS valve
pressure (Approx. 3/5)
pressure.
40-658 PC360LC-10
40 Troubleshooting
mode)

If normal oil pressure is not obtained after adjustment, check LS valve
16 Malfunction of LS valve (front) for malfunction (setting of spring) and internal failure (locked or trapped
LS spool).
If normal oil pressure is not obtained after adjustment, check LS valve
17 Malfunction of LS valve (rear) for malfunction (setting of spring) and internal failure (locked or trapped
LS spool).
If sensor output voltage is normal in checks on causes 1 and 2,
Malfunction of servo piston or determine that servo piston is normal.
18 PC valve (*)
If no failure is found by above checks, piston pump may malfunction, or
have internal failure.
19 Malfunction of piston pump
Check hydraulic tank strainer and return filter element for metal
particles.
(*) Since PC valve is built in servo piston, servo piston assembly must be replaced if PC valve is defective.
PC360LC-10 40-659
40 Troubleshooting
mode)
H-3 Any of work equipment, swing and travel does not work (PC400-FT5-400-A-Z1-A)
Failure • All work equipment, travel, and swing systems do not work.
Related information • Perform all troubleshooting with working mode in power mode (P).
a Be ready with engine stopped, then troubleshoot with engine at full
speed.
Measurement Solenoid output
Malfunction of PPC lock Lock lever pressure
1 conditions
solenoid valve
• Hydraulic oil at LOCK position 0 MPa {0 kg/cm2 }
temperature: Within 2.84 to 3.43 MPa
operation range at FREE position
{29 to 35 kg/cm2 }
a Be ready with engine stopped, then troubleshoot with engine at full
speed.
Measurement Control circuit source
Control lever pressure
conditions
Malfunction of self-pressure
2 reducing valve • Hydraulic oil When all control levers 2.84 to 3.43 MPa
temperature: Within are in NEUTRAL
operation range position {29 to 35 kg/cm2 }
a Relief valve of self-pressure reducing valve cannot be adjusted. If it

is defective, replace self-pressure reducing valve assembly.
Piston pump may malfunction or have internal defect. Check it by
following method.
3 Defective piston pump
• Crank the engine with main oil pressure pickup port plug. If oil flows
out, it is in normal.
Pump shaft may not rotate due to some internal defect of damper.
4 Defective damper
Check the damper.
40-660 PC360LC-10
40 Troubleshooting
mode)
H-4 Unusual sound is heard from around hydraulic pump (PC400-BAA-400-A-Z0-A)
Failure • Unusual sound is heard from around hydraulic pump

Related information —
Check hydraulic oil level directly.
1 Lowering of hydraulic oil level (Reference) If the hydraulic oil level is low while no hydraulic oil leaks to
the outside, it is assumed that hydraulic oil may flow in the flywheel
chamber due to a pump shaft seal damage.
2 Defective hydraulic oil Air may mix in hydraulic oil. Check it for bubbles or milky state.
Cap of the hydraulic tank cap may be clogged, causing negative
3 Clogging of hydraulic tank cap
pressure inside the tank. Check the cap.
Clogging of hydraulic tank Strainer in the hydraulic tank may be clogged, causing negative
4 pressure in the suction circuit. Check the strainer.
strainer
Clogging of hydraulic tank Check the return filter in the hydraulic tank may be clogged, especially
5 by metallic materials. Check the return filter.
return filter
If any metallic materials are detected in Cause 4 and 5 above, piston
6 Defective piston pump
pump may have internal defect.
PC360LC-10 40-661
40 Troubleshooting
mode)
H-5 Fine control performance or response is poor　 (PC300-FTB-400-A-Z0-A)
Failure • Fine control performance or response is poor.

• If failure codes are displayed, perform troubleshooting for them first. (DKR0MA, DKR1MA,
Related DXE0KA, DAXE0KB)
information • Signal voltage from swash plate sensor can be checked with monitoring function. (Code: F
pump side 01138, R pump side 01140)
1 plate sensor (front)
Sensor output L.H. track only: Running idle off
2 plate sensor (rear)
Sensor output R.H. track only: Running idle off
Approx. 1.5 MPa
3 lever: NEUTRAL
moved
4 Clogged orifice in LS circuit Orifice may be clogged. Check it.
L.H. track:
Running idle off
Lever moved
halfway
pressure pressure 1
R.H. track:
Running idle off
Lever moved
halfway
pressure pressure 1
40-662 PC360LC-10
40 Troubleshooting
mode)

spool).
8 (rear) malfunction (setting of spring) and internal failure (locked or trapped LS
spool).
If sensor output voltage is normal in checks on causes 1 and 2 is normal,
9 Malfunction of servo piston determine that servo piston is normal.
PC360LC-10 40-663
40 Troubleshooting
mode)
H-6 Speed or power of boom is low (PC300-A8B-400-A-Z0-A)
Failure • Speed or power of boom is low.

• If failure codes are displayed, perform troubleshooting for them first. (DXE5KB, DXE6KA,
DXE6KB)
• Boom RAISE PPC pressure can be checked with monitoring function. (Code: 07400)
Related • Current to merge-divider (main) solenoid can be checked with monitoring function. (Code:
information 08000)
• Current to merge-divider (LS) solenoid can be checked with monitoring function. (Code:
08001)
• F pump pressure and R pump pressure can be checked with monitoring function. (Code: F
pump pressure 01100, R pump pressure 01101)
R.H. work
Malfunction of right PPC equipment control NEUTRAL 0 MPa {0 kg/cm2}
1 valve (boom circuit)
PPC valve output lever
pressure R.H. work
Boom RAISE or 2.84 to 3.43 MPa
equipment control {29 to 35 kg/cm2}
LOWER
lever
a If boom lacks speed, check all work equipment speeds. If any failure is
found, perform troubleshooting on causes (3) to (5) related to merge-
divider valve failure.
a Perform troubleshooting with engine running at full speed.
Malfunction of merge-
2 divider valve assembly Max. 4.6/4.0
Boom RAISE/LOWER
seconds
Time required for
Max. 4.5/3.7
work equipment Arm IN/OUT
seconds
to move
Max. 3.8/2.9
Bucket CURL/DUMP
seconds
All work equipment control levers in 0 to 0.49 MPa {0
Main EPC output NEUTRAL to 5 kg/cm2}
Malfunction of merge- pressure
3 Bucket CURL and Arm IN hydraulic 2.84 to 3.43 MPa
divider main EPC valve {29 to 35 kg/cm2}
relief
All work equipment control levers in
0 mA
NEUTRAL
EPC current
Bucket CURL and Arm IN hydraulic
800 to 1000 mA
relief
LS-EPC output NEUTRAL to 5 kg/cm2}
Malfunction of merge- pressure 2.84 to 3.43 MPa
4 Bucket CURL and Arm IN hydraulic
divider LS-EPC valve {29 to 35 kg/cm2}
relief
0 mA
NEUTRAL
EPC current
800 to 1000 mA
relief
a Release remaining pressure from hydraulic tank and piping and then
perform troubleshooting with engine stopped.
Malfunction of merge- • Check for stuck or seized main spool in merge-divider valve body.
5 divider main spool
(Spool must move smoothly.)
• Remove main spool from valve body and check it for defects and dirt.
• Take care not to let foreign matter enter valve when re-installing spool.
40-664 PC360LC-10
40 Troubleshooting
mode)

Malfunction of merge- • Check for stuck or seized LS spool in merge-divider valve body.
6 divider LS spool
• Remove LS spool from valve body and check it for defects and dirt.
Malfunction of boom • Check for stuck or seized boom spool in control valve body.
7 control valve (spool)
• Remove boom spool from valve body and check it for defects and dirt.
33.15 to 36.77
Boom relief
Boom RAISE hydraulic relief MPa {338 to
pressure
375 kg/cm2}
a Check hydraulic drift of boom cylinder with engine stopped.
Hydraulic oil temperature within If visible hydraulic
Malfunction of boom operating range, bucket wit rated drift is observed,
Hydraulic drift
control valve (pressure load, boom horizontal, arm cylinder control valve is
8 compensation valve) fully retracted defective.
(boom RAISE side)
a Check whether boom cylinder moves slowly when performing hydraulic
relief of other work equipment. (If boom cylinder moves, control valve is
defective.)
a If any failure is found in either of above check items, interchange
pressure compensation valves on RAISE and LOWER sides, and
check whether failure symptom changes.
(Pressure compensation valves have different area ratio, so return them
to their original positions after test.)
16.66 to 19.6
At low-pressure
MPa {170 to
setting
Boom relief Boom LOWER 200 kg/cm2}
pressure hydraulic relief 29.4 to 33.32
At high-pressure
MPa {300 to
setting
340 kg/cm2}
a Check hydraulic drift of boom cylinder with engine stopped.
Malfunction of boom
control valve (pressure Hydraulic oil temperature within If visible hydraulic
9 compensation valve)
Hydraulic drift operating range, arm cylinder fully drift is observed,
(boom LOWER side) extended, machine raised off ground control valve is
defective.
a Check whether boom cylinder moves slowly when performing hydraulic
relief of other work equipment. (If boom cylinder moves, control valve is
defective.)
pressure compensation valves on RAISE and LOWER sides, and
(Pressure compensation valves have different area ratio, so return them
to their original positions after test.)
PC360LC-10 40-665
40 Troubleshooting
mode)

• Check for locked or trapped boom regeneration valve in control valve
body.
Malfunction of boom
(Valve must move smoothly.)
10 control valve (regeneration • Check that regeneration valve (check valve ) is seated on control valve
valve)
in position (it is not stopped halfway), and then remove it from control
valve body and check it for dents and dirt.
• Check spring of check valve for setting and deformation.
• Take care not to let foreign matter enter control valve when re-installing
check valve.
Boom relief Boom RAISE hydraulic relief, arm IN 33.15 to 36.77
pressure and arm hydraulic relief, and arm OUT MPa {338 to
relief pressure hydraulic relief 375 kg/cm2}
Malfunction of boom a Among above relief pressures, if arm OUT relief pressure and boom
11 control valve (safety valve RAISE relief pressure is below standard relief pressure, safety valve
for lock valve) may be defective. Check safety valve for damaged sealing material.
a Since relief pressure cannot be adjusted with safety valve installed on
machine, replace safety valve assembly if safety valve is found to be
defective.
(Reference) Safety valve circuit connects to both boom RAISE and arm
OUT circuits via check valve. Determine that boom lock valve is defective if
arm IN or OUT relief pressure is normal.
• Check that pilot piston and poppet are seated on lock valve body in
position (they are not trapped halfway).
• Check for locked or trapped pilot piston and poppet in lock valve body
(pilot piston and poppet must move smoothly).
Malfunction of boom
12 control valve (lock valve) • Remove pilot piston and poppet from valve body and check them for
defects and dirt.
• Check poppet spring for setting and deformation.
• Take care not to let foreign matter enter lock valve when re-installing
pilot piston and poppet.
33.15 to 36.77
Boom relief
Boom RAISE hydraulic relief MPa {338 to
pressure
375 kg/cm2}
Malfunction of boom
13 control valve (suction a If boom RAISE relief pressure is below standard value, suction valve
valve) (boom RAISE side) may be defective. Check it.
• Check that check valve is seated on valve body in position (it is not
trapped halfway).
• Remove check valve from valve body and check it for defects and dirt.
• Check spring for setting and deformation.
check valve.
40-666 PC360LC-10
40 Troubleshooting
mode)

16.66 to 19.6
At low-pressure
MPa {170 to
setting
Boom relief Boom LOWER 200 kg/cm2}
pressure hydraulic relief 29.4 to 33.32
At high-pressure
MPa {300 to
setting
Malfunction of boom 340 kg/cm2}
control valve (suction- a If boom LOWER relief pressure is below standard value, suction-safety
14 safety valve) (boom
valve may be defective. Check it.
LOWER side)
trapped halfway).
defective.
(Reference) Safety valve on boom LOWER side has 2-stage relief
pressure setting because this machine is equipped with machine push-up
function.
All work equipment control lever in 3.9 ± 1.0 MPa {40
Malfunction of boom LS differential NEUTRAL ± 10 kg/cm2}
15 control valve (LS shuttle pressure 2.45 ± 0.1 MPa
valve) Fine control of boom RAISE {25 ± 1 kg/cm2}
If LS differential pressure is above standard value, LS shuttle valve may be
defective. Clean check valve seat on shuttle valve block of boom control
valve.Also check for defects on check valve.
Malfunction of LS shuttle
16 valve (L.H. travel control Clean check valve seat on shuttle valve block of L.H. travel control valve.
valve)
17 valve (bucket control valve) Clean check valve seat on shuttle valve block of bucket control valve.
18 valve (service valve) Clean check valve seat on shuttle valve block of service valve.

19 Defective boom cylinder running at full speed.
Leakage from
Boom RAISE hydraulic relief Max. 20 cc/min
boom cylinder
PC360LC-10 40-667
40 Troubleshooting
mode)
H-7 Speed or power of arm is low (PC300-A8C-400-A-Z0-A)
Failure • Speed or power of arm is low.

• If failure codes are displayed, perform troubleshooting for them first. (DHS3MA, DXE5KA,
DXE5KB, DXE6KA, DXE6KB)
• Arm IN PPC pressure can be checked with monitoring function. (Code: 07200)
information 08000)
08001)
L.H. work
Malfunction of left PPC equipment control NEUTRAL 0 MPa {0 kg/cm2}
1 valve (arm circuit)
pressure L.H. work 2.84 to 3.43 MPa
equipment control Arm IN or OUT {29 to 35 kg/cm2}
lever
a If arm lacks speed, check all work equipment speeds. If any failure is
found, perform troubleshooting on causes 3 to 6 related to merge-
Boom RAISE/LOWER
seconds
Time required for
Max. 4.5/3.7
seconds
to move
Max. 3.8/2.9
Bucket CURL/DUMP
seconds
relief
0 mA
NEUTRAL
EPC current
800 to 1000 mA
relief
relief
0 mA
NEUTRAL
EPC current
800 to 1000 mA
relief
40-668 PC360LC-10
40 Troubleshooting
mode)

Malfunction of merge- • Check for locked or trapped main spool in merge-divider valve body.
5 divider main spool (Spool must move smoothly.)
• Take care not to let foreign matter enter valve when re-installing main
spool.
Malfunction of merge- • Check for locked or trapped LS spool in merge-divider valve body.
6 divider LS spool (Spool must move smoothly.)
• Take care not to let foreign matter enter valve when re-installing LS
spool.
Malfunction of arm control • Check for locked or trapped arm spool in control valve body.
7 valve (spool) (Spool must move smoothly.)
• Remove arm spool from valve body and check it for defects and dirt.
• Take care not to let foreign matter enter valve when re-installing arm
spool.
33.15 to 36.77
Arm relief
Arm IN hydraulic relief MPa {338 to
pressure
375 kg/cm2}
a Check hydraulic drift of arm cylinder with engine stopped.
Malfunction of arm control
Hydraulic drift operating range, bucket with rated drift is observed,
valve (pressure control valve is
8 compensation valve) (arm load, arm cylinder fully extended
defective.
IN side)
a Check whether arm cylinder moves slowly when performing hydraulic
relief of other work equipment. (If arm cylinder moves, control valve is
defective.)
pressure compensation valves on arm IN and OUT sides, and check
whether failure symptom changes.
(Pressure compensation valves have different area ratio, so be sure to
return them to their original positions after test.)
PC360LC-10 40-669
40 Troubleshooting
mode)

33.14 to 36.77
Arm relief
Arm OUT hydraulic relief MPa {338 to
pressure
375 kg/cm2}
Hydraulic drift operating range, bucket with rated drift is observed,
valve (pressure control valve is
9 compensation valve) (arm load, arm cylinder fully retracted:
defective.
OUT side)
defective.)
pressure compensation valves on arm IN and OUT sides, and check
• Check for locked or trapped arm regeneration valve in control valve
body.
Malfunction of arm control (Regeneration valve must move smoothly.)
10 valve (regeneration valve) • Check that regeneration valve (check valve ) is seated on control valve
in position (it is not trapped halfway), and then remove it from control
valve body and check it for defects and dirt.
• Take care not to let foreign matter enter valve when re-installing check
valve.
Measurement condition Hydraulic drift
If visible hydraulic
• Hydraulic oil temperature within operating range,
drift is observed,
bucket with rated load, arm cylinder fully extended
control valve is
•
defective.
Malfunction of arm control perform troubleshooting with engine stopped.
11 valve (quick return valve) • Check that pilot spool and check valve are seated on valve body in
• Check for locked or trapped pilot spool and check valve in quick return
valve body.
(Pilot spool and check valve must move smoothly.)
• Remove pilot spool and check valve from valve body and check them
for defects and dirt.
pilot spool and check valve.
40-670 PC360LC-10
40 Troubleshooting
mode)

pressure and arm hydraulic relief, and arm OUT MPa {338 to
relief pressure hydraulic relief 375 kg/cm2}
a Among above relief pressures, if arm OUT relief pressure and boom
12 valve (safety valve for lock RAISE relief pressure is below standard value, safety valve may be
valve)
defective. Check safety valve for damaged sealing material.
machine, replace safety valve if safety valve is found to be defective.
(pilot piston and poppet should move smoothly).
13 valve (lock valve) • Remove pilot piston and poppet from valve body and check them for
defects and dirt.
• Take care not to let foreign matter enter valve when re-installing piston
and poppet.
33.15 to 36.77
Arm relief
Arm OUT hydraulic relief MPa {338 to
pressure
375 kg/cm2}
14 valve (suction valve) (arm a If arm OUT relief pressure is below standard value, suction valve (check
OUT side) valve) may be defective. Check it.
trapped halfway).
• Remove check valve from valve body and check it for defects and dirt.
• Check spring for setting and deformation.
• Take care not to let foreign matter enter valve when re-installing check
valve.
33.15 to 36.77
Arm relief
Arm IN hydraulic relief MPa {338 to
pressure
375 kg/cm2}
15 valve (suction-safety valve) a If arm IN relief pressure is below standard value, suction-safety valve
(arm IN side) may be defective. Check it.
• Check that check valve of suction-safety valve is seated on valve body
in position (it is not trapped halfway).
defective.
PC360LC-10 40-671
40 Troubleshooting
mode)

LS differential NEUTRAL ± 10 kg/cm2}
16 valve (LS shuttle valve) pressure 2.45 ± 0.1 MPa
Finely moved to arm IN and OUT
{25 ± 1 kg/cm2}
a If LS differential pressure is above standard value, LS shuttle valve may
be defective. Clean check valve seat on shuttle valve block of arm
control valve.Also check for defects on check valve.
Clean check valve seat on shuttle valve block of R.H. travel control valve,
17 valve (R.H. travel control
valve) and then check it.

18 Defective arm cylinder running at full speed.
Leakage from
Arm IN hydraulic relief Max. 20 cc/min
arm cylinder
40-672 PC360LC-10
40 Troubleshooting
mode)
H-8 Speed or power of bucket is low (PC300-A8D-400-A-Z0-A)
Failure • Speed or power of bucket is low.

• If failure codes are displayed, perform troubleshooting for them first. (DHS4MA, DXE5KA,
DXE5KB, DXE6KA, DXE6KB)
• Bucket CURL PPC pressure can be checked with monitoring function. (Code: 07300)
information 08000)
08001)
R.H. work
Malfunction of right PPC equipment control NEUTRAL 0 MPa {0 kg/cm2}
1 valve (bucket circuit)
pressure R.H. work 2.84 to 3.43 MPa
equipment control Arm IN or OUT {29 to 35 kg/cm2}
lever
a If bucket lacks speed, check all work equipment speeds. If any failure is
found, perform troubleshooting on causes 3 to 6 related to merge-
Boom RAISE/LOWER
seconds
Time required for
Max. 4.5/3.7
seconds
to move
Max. 3.8/2.9
Bucket CURL/DUMP
seconds
relief
0 mA
NEUTRAL
EPC current
800 to 1000 mA
relief
relief
0 mA
NEUTRAL
EPC current
800 to 1000 mA
relief
PC360LC-10 40-673
40 Troubleshooting
mode)

5 divider main spool (Spool must move smoothly.)
main spool.
6 divider LS spool (Spool must move smoothly.)
LS spool.
Malfunction of bucket • Check for locked or trapped bucket spool in control valve body.
7 control valve (spool) (Spool must move smoothly.)
• Remove bucket spool from valve body and check it for defects and dirt.
bucket spool.
33.15 to 36.77
Bucket relief
Bucket CURL hydraulic relief MPa {338 to
pressure
375 kg/cm2}
a Check hydraulic drift of bucket cylinder with engine stopped.
Hydraulic oil temperature within
operating range, bucket with rated If visible hydraulic
Malfunction of bucket load, arm cylinder fully retracted, drift is observed,
Hydraulic drift
control valve (pressure bucket cylinder fully extended, boom control valve is
top face horizontal defective.
(bucket CURL side)
a Check whether bucket cylinder moves slowly when performing
hydraulic relief of other work equipment. (If bucket cylinder moves,
control valve is defective.)
pressure compensation valves on bucket CURL and DUMP sides, and
40-674 PC360LC-10
40 Troubleshooting
mode)

33.15 to 36.77
Bucket relief
Bucket DUMP hydraulic relief MPa {338 to
pressure
375 kg/cm2}
a Check hydraulic drift of bucket cylinder with engine stopped.
Hydraulic oil temperature within
operating range, bucket with no load, If visible hydraulic
Malfunction of bucket arm cylinder fully retracted, bucket drift is observed,
Hydraulic drift
control valve (pressure cylinder fully retracted, boom top control valve is
face horizontal defective.
(bucket DUMP side)
hydraulic relief of other work equipment. (If bucket cylinder moves,
control valve is defective.)
pressure compensation valves on bucket CURL and DUMP sides, and
33.15 to 36.77
Bucket relief
Bucket CURL hydraulic relief MPa {338 to
Malfunction of bucket pressure
375 kg/cm2}
control valve (suction-
10 safety valve) (bucket CURL • If bucket CURL relief pressure is below standard value, suction valve
may be defective. Check it.
side) • Check that check valve of suction-safety valve is seated on valve body
defective.
33.15 to 36.77
Bucket relief
Bucket DUMP hydraulic relief MPa {338 to
Malfunction of bucket pressure
375 kg/cm2}
control valve (suction- • If bucket DUMP relief pressure is below standard value, suction valve
11 safety valve) (bucket
may be defective. Check it.
DUMP side) • Check that check valve of suction-safety valve is seated on valve body
defective.
Malfunction of bucket LS differential NEUTRAL ± 10 kg/cm2}
12 control valve (LS shuttle pressure Finely moved to bucket CURL or 2.45 ± 0.1 MPa
valve) DUMP {25 ± 1 kg/cm2}
a If LS differential pressure is above standard value, LS shuttle valve may
be defective. Clean check valve seat on shuttle valve block of bucket
control valve.Also check for defects on check valve.
PC360LC-10 40-675
40 Troubleshooting
mode)

Clean check valve seat on shuttle valve block of L.H. travel control valve,
13 valve (L.H. travel control
valve) and then check it.

14 Defective bucket cylinder running at full speed.
Leakage from
Bucket CURL hydraulic relief Max. 20 cc/min
bucket cylinder
40-676 PC360LC-10
40 Troubleshooting
mode)
H-9 Work equipment does not move in single operation (PC300-FTC-400-A-Z0-A)
(1) Boom does not move in single operation.

Failure (2) Arm does not move in single operation.
(3) Bucket does not move in single operation.
• If failure codes are displayed, perform troubleshooting for them first. (DHS3MA, DHS4MA,
DHS8MA, DHSDMA)
• PPC pressure of each work equipment can be checked with monitoring function.
Related Monitoring codes for them are shown below.
information Boom RAISE PPC pressure: 07400
Arm IN PPC pressure: 07200
Bucket CURL PPC pressure: 07300
Bucket DUMP PPC pressure: 07301
1 Malfunction of PPC valve Work equipment 0 MPa {0 kg/cm2}
NEUTRAL
PPC valve output control levers
pressure Work equipment 2.84 to 3.43 MPa
Operated
control levers {29 to 35 kg/cm2}
Malfunction of boom • Check for locked or trapped boom spool in control valve body.
• Remove boom spool from valve body and check it for defects and dirt.
boom spool.
Malfunction of arm control • Check for locked or trapped arm spool in control valve body.
3 valve (spool) (Spool must move smoothly.)
arm spool.
bucket spool.
(Reference) While work equipment is moved in single operation, if pump pressure remains at approx. 4 MPa
{approx. 40 kg/cm2}, control valve spool probably stays at NEUTRAL position.(All oil from pump is drained to
tank through unload valve.)
PC360LC-10 40-677
40 Troubleshooting
mode)
H-10 Hydraulic drift of boom is large (PC300-MS3-400-A-Z0-A)
Failure • Hydraulic drift of boom is large.

Related • Perform all troubleshooting with working mode set in P mode.
information
1 Defective boom cylinder running at full speed.
Leak from boom
Boom RAISE hydraulic relief Max. 20 cc/min
cylinder
pressure and arm hydraulic relief, and arm OUT MPa {338 to 375
relief pressure hydraulic relief kg/cm2}
Malfunction of boom a Among above relief pressures, if arm OUT relief pressure and boom
2 control valve (safety valve RAISE relief pressure is below standard value, safety valve may be
for lock valve) defective. Check safety valve for damaged sealing material.
defective.
Malfunction of boom
3 control valve (lock valve) (pilot piston and poppet must move smoothly).
• Remove pilot piston and poppet from valve body and check them for
defects and dirt.
40-678 PC360LC-10
40 Troubleshooting
mode)
H-11 Hydraulic drift of arm is large (PC300-MS4-400-A-Z0-A)
Failure • Hydraulic drift of arm is large.

information
1 Defective arm cylinder running at full speed.
Leak from arm
Arm IN hydraulic relief Max. 20 cc/min
cylinder
pressure and arm hydraulic relief, and arm OUT MPa {338 to 375
relief pressure hydraulic relief kg/cm2}
Malfunction of arm control a Among above relief pressures, if arm OUT relief pressure and boom
2 valve (safety valve for lock RAISE relief pressure is below standard value, safety valve may be
valve) defective. Check safety valve for damaged sealing material.
defective.
3 valve (lock valve) (pilot piston and poppet must move smoothly).
• Remove pilot piston and poppet from valve body and check them for
defects and dirt.
33.15 to 36.77
Arm relief
Arm IN hydraulic relief MPa {338 to 375
pressure
kg/cm2}
4 valve (suction-safety valve) a If arm IN relief pressure is below standard value, suction-safety valve
(arm IN side) may be defective. Check it.
• Check that check valve of suction-safety valve is seated on valve body
defective.
Malfunction of arm control perform troubleshooting with engine stopped.
5 valve (spool) • Check for locked or trapped arm spool in control valve body.
PC360LC-10 40-679
40 Troubleshooting
mode)

defective.)
6 valve (pressure a If any failure is found in either of above check items, interchange
compensation valve) pressure compensation valves on arm IN and OUT sides, and check
40-680 PC360LC-10
40 Troubleshooting
mode)
H-12 Hydraulic drift of bucket is large (PC300-MS2-400-A-Z0-A)
Failure • Hydraulic drift of bucket is large.

information
1 Defective bucket cylinder running at full speed.
Leak from bucket
Bucket CURL hydraulic relief Max. 20 cc/min
cylinder
33.15 to 36.77
Bucket relief Bucket CURL or DUMP hydraulic
Malfunction of bucket MPa {338 to 375
pressure relief
2 control valve (suction- kg/cm2}
safety valve)
a If relief pressure is below standard value, suction-safety valve may be
defective.
a You can replace suction-safety valve with other one and check whether
failure symptom changes for judgment.
bucket spool.
hydraulic relief of other work equipment.
(If bucket cylinder moves, control valve is defective.)
Malfunction of bucket
4 control valve (pressure a If any failure is found in above check item, interchange pressure
compensation valve) compensation valves on bucket CURL and DUMP sides, and check
PC360LC-10 40-681
40 Troubleshooting
mode)
H-13 Time lag of work equipment is large (PC300-FTD-400-A-Z0-A)
Failure • Time lag of work equipment is large.

Related • If failure codes are displayed, perform troubleshooting for them first. (DXE0KA, DXE0KB)
information • F pump pressure and R pump pressure can be checked with monitoring function. (Code: F
Approx. 1.5 MPa
1 lever: NEUTRAL
moved
• Check for locked or trapped boom regeneration valve in control valve
Malfunction of boom body.
2 control valve (regeneration (Regeneration valve must move smoothly.)
valve) • Check that regeneration valve (check valve ) is seated on control valve
• Check for locked or trapped arm regeneration valve in control valve
Malfunction of arm control body.
3 valve (regeneration valve) (Regeneration valve must move smoothly.)
• Check that regeneration valve (check valve ) is seated on control valve
a Check relief pressure of each work equipment. If relief pressure only of
Malfunction of boom boom cylinder head end is unusual, suction-safety valve of boom
4 control valve (suction- control valve may malfunction.
safety valve)
arm cylinder bottom end is unusual, suction-safety valve of arm control
5 valve (suction-safety valve) valve may malfunction.
Malfunction of bucket bucket cylinder head end is unusual, suction-safety valve of bucket
6 control valve (suction- control valve may malfunction.
safety valve)
40-682 PC360LC-10
40 Troubleshooting
mode)

a Check whether boom cylinder moves slowly to RAISE side when
performing hydraulic relief of other work equipment. (If boom cylinder
Malfunction of boom moves, control valve is defective.)
control valve (pressure a If any failure is found in above check item, interchange pressure
compensation valves between both ports, and check whether failure
(boom RAISE side) symptom changes.
Malfunction of boom
control valve (pressure a Check whether boom cylinder moves slowly to LOWER side when
8 compensation valve) performing hydraulic relief of other work equipment. (If boom cylinder
(boom LOWER side) moves, control valve is defective.)
valve (pressure a Check whether arm cylinder moves slowly to arm IN side when
9 compensation valve) (arm performing hydraulic relief of other work equipment. (If arm cylinder
IN side) moves, control valve is defective.)
valve (pressure a Check whether arm cylinder moves slowly to arm OUT side when
10 compensation valve) (arm performing hydraulic relief of other work equipment. (If arm cylinder
OUT side) moves, control valve is defective.)
control valve (pressure a Check whether bucket cylinder moves slowly to bucket CURL side
11 compensation valve) when performing hydraulic relief of other work equipment. (If bucket
(bucket CURL side) cylinder moves, control valve is defective.)
control valve (pressure a Check whether bucket cylinder moves slowly to bucket DUMP side
12 compensation valve) when performing hydraulic relief of other work equipment. (If bucket
(bucket DUMP side) cylinder moves, control valve is defective.)
PC360LC-10 40-683
40 Troubleshooting
mode)
H-14 When part of work equipment is relieved singly, other parts of work
equipment move (PC300-FT4-400-A-Z0-A)
Failure • Other wok equipment moves when one of work equipment is relieved.
information
When work equipment other than boom is hydraulically relieved singly, if
boom moves to RAISE side arbitrarily, pressure compensation valve on
Malfunction of boom boom RAISE side may malfunction.
control valve (pressure
1 compensation valve) a Pressure compensation valve is equipped with outer seal, inner seal,
(boom RAISE side) and LS check valve (ball).
Since slipper seal is installed to inner seal, damage on O-ring inside
inner seal cannot be checked visually.
When work equipment other than arm is hydraulically relieved singly, if arm
valve (pressure
2 compensation valve) (arm moves to IN side arbitrarily, pressure compensation valve on arm IN side
may malfunction.
IN side)
When work equipment other than bucket is hydraulically relieved singly, if
3 compensation valve) bucket moves to CURL side arbitrarily, pressure compensation valve on
bucket CURL side may malfunction.
(bucket CURL side)
When work equipment other than bucket is hydraulically relieved singly, if
4 compensation valve) bucket moves to DUMP side arbitrarily, pressure compensation valve on
bucket DUMP side may malfunction.
(bucket DUMP side)
40-684 PC360LC-10
40 Troubleshooting
mode)
H-15 One-touch power maximizing function does not work (PC300-FGL-400-A-Z1-A)
Failure • One-touch power maximizing function does not work..

information • If failure codes are displayed, perform troubleshooting for them first. (DWK0KA, DWK0KB)
Malfunction of 2-stage
1 2-stage relief Swing lock switch OFF 0 MPa {0 kg/cm2}
relief solenoid valve
solenoid output 2.84 to 3.43 MPa
pressure Swing lock switch ON {29 to 35 kg/cm2}
33.15 to 36.77
Normal hydraulic Hydraulic relief of MPa {338 to 375
relief bucket only
Defective adjustment or kg/cm2}
Front pump main
2 malfunction of main relief relief pressure Hydraulic relief
35.60 to 39.23
valve (front) during one-touch Hydraulic relief of
MPa {363 to 400
power bucket only
kg/cm2}
maximizing
If normal relief pressure is not obtained after adjustment, check main relief
valve for malfunction (setting of spring) and internal failure (defective valve
seat).
33.15 to 36.77
Normal hydraulic Hydraulic relief of MPa {338 to 375
relief arm only
Defective adjustment or kg/cm2}
Rear pump main
3 malfunction of main relief relief pressure Hydraulic relief
35.60 to 39.23
valve (rear) during one-touch Hydraulic relief of
MPa {363 to 400
power arm only
kg/cm2}
maximizing
If normal relief pressure is not obtained after adjustment, check main relief
valve for malfunction (setting of spring) and internal failure (defective valve
seat).
PC360LC-10 40-685
40 Troubleshooting
mode)
H-16 Machine push up function does not work (PC300-FTG-400-A-Z1-A)
Failure • Machine push-up function does not work.

information
Malfunction of machine Machine push-up switch: OFF 2.84 to 3.43 MPa
1 push-up solenoid valve Machine push-up (solenoid is energized.) {29 to 35 kg/cm2}
solenoid output
pressure Machine push-up switch: ON
0 MPa {0 kg/cm2}
(solenoid is de-energized.)
16.66 to 19.6
Machine push-up MPa {170 to 200
Single hydraulic switch: OFF kg/cm2}
Relief pressure relief of boom
Malfunction of boom 29.4 to 33.32
2 control valve (safety valve) LOWER Machine push-up MPa {300 to 340
switch: ON kg/cm2}
Safety valve of boom control valve (Lo) (high-pressure setting side of
cylinder head end) may malfunction.
defective.
Malfunction of boom
If no failure is found by checks on causes 1 and 2, suction valve of boom
3 control valve (suction cylinder head end may malfunction. Check for setting and defects of spring.
valve)
40-686 PC360LC-10
40 Troubleshooting
mode)
H-17 In combined operation of work equipment, equipment having

heavier load moves slower (PC300-D34-400-A-Z0-A)
Failure • In combined operation of work equipment, equipment having heavier load moves slower.
Related
information
Operations
Malfunction of control valve Heavier load side Smaller load side
combined
on smaller load side Boom RAISE and
1 (pressure compensation Boom RAISE Arm IN
arm IN
valve) (arm IN) Pressure compensation valve of control valve on smaller load side may
malfunction.
Operations
combined
on smaller load side Boom RAISE and
2 (pressure compensation Arm OUT Boom RAISE
arm OUT
valve) (boom RAISE) Pressure compensation valve of control valve on smaller load side may
malfunction.
Operations
Heavier load side Smaller load side
combined
Boom RAISE and
Boom RAISE Bucket CURL
bucket CURL
Malfunction of control valve Pressure compensation valve of control valve on smaller load side may
on smaller load side malfunction.
3 (pressure compensation
Operations
valve) (bucket CURL) Heavier load side Smaller load side
combined
Arm OUT and
Arm OUT Bucket CURL
bucket CURL
Pressure compensation valve of control valve on smaller load side may
malfunction.
Operations
combined
on smaller load side Boom LOWER
4 (pressure compensation Arm OUT Boom LOWER
and arm OUT
valve) (boom LOWER) Pressure compensation valve of control valve on smaller load side may
malfunction.
a Pressure compensation valve is equipped with outer seal, inner seal, and LS check valve (ball).
Since slipper seal is installed to inner seal, damage on O-ring inside inner seal cannot be checked visually.
PC360LC-10 40-687
40 Troubleshooting
mode)
H-18 In combined operations of swing and boom RAISE, boom rising

speed is low (PC300-D35-400-A-Z0-A)
Failure • In combined operations of swing and boom RAISE, boom rising speed is low.
Related • If boom rising speed is low in single operation of boom RAISE, perform troubleshooting for
information H-6 first.
Malfunction or defective LS selector valve (LS separator valve) of swing control valve may
sealing of swing control malfunction, or sealing of LS selector valve may be defective.
1 valve (LS selector valve
Check piston of LS selector valve (LS separator valve) for getting trapped
(LS separator valve)) and defects, and spring for setting.
40-688 PC360LC-10
40 Troubleshooting
mode)
H-19 In combined operations of swing and travel, travel speed drops

largely (PC300-D26-400-A-Z0-A)
Failure • Travel speed drops largely in combined operation of swing and travel.
Related • If travel speed is low in single operation of travel, perform troubleshooting for H-21 first.
information
Malfunction of R.H. travel LS shuttle valve of R.H. travel control valve may malfunction.
1 control valve (LS shuttle
valve) Clean check valve seat on shuttle valve block of R.H. travel control valve.
Malfunction of arm control LS shuttle valve of arm control valve may malfunction.
2 valve (LS shuttle valve)
Clean check valve seat on shuttle valve block of arm control valve.
PC360LC-10 40-689
40 Troubleshooting
mode)
H-20 Machine does not travel straight (PC300-FTF-400-A-Z0-A)
Failure • Machine deviates during travel.

Related • If failure codes are displayed, perform troubleshooting for them first. (DW91KA, DW91KB,
information DHS3MA, DXE5KA, DXE5KB, DXE6KA, DXE6KB)
• Travel PPC pressure can be checked with monitoring function. (Code: 01882)
Malfunction of R.H. travel
1 R.H. travel PPC NEUTRAL 0 MPa {0 kg/cm2}
PPC valve R.H travel control
valve output FORWARD and 2.84 to 3.43 MPa
pressure lever
REVERSE {29 to 35 kg/cm2}
Malfunction of L.H. travel NEUTRAL 0 MPa {0 kg/cm2}
2 L.H. travel control
PPC valve L.H. travel PPC
lever FORWARD and 2.84 to 3.43 MPa
valve output REVERSE {29 to 35 kg/cm2}
pressure Difference in output pressure Max. 0.4 MPa
between L.H. and R.H. PPC valves {Max. 4 kg/cm2 }
Malfunction of self- Control circuit 2.84 to 3.43 MPa
3 pressure reducing valve source pressure All levers in NEUTRAL {29 to 35 kg/cm2}
a Since relief valve of self-pressure reducing valve is not adjustable,
replace self-pressure reducing valve assembly if normal pressure is not
obtained.
L.H. track:
Running idle off
Lever moved
halfway
pressure pressure 1
R.H. track:
Running idle off
Lever moved
halfway
pressure pressure 1
spool).
40-690 PC360LC-10
40 Troubleshooting
mode)

7 (rear) malfunction (setting of spring) and internal failure (locked or trapped LS
spool).
Malfunction of travel Both levers in
8 junction solenoid valve 0 MPa {0 kg/cm2}
Solenoid valve Travel control NEUTRAL
outlet pressure lever When either lever 2.84 to 3.43 MPa
is operated {29 to 35 kg/cm2}
• Check for locked or trapped travel junction valve spool in merge-divider
Malfunction of travel valve body.
9 junction valve (spool)
• Remove travel junction valve spool from valve body and check it for
defects and dirt.
Malfunction of R.H.travel • Check for locked or trapped travel spool in control valve body.
• Remove travel spool from valve body and check it for defects and dirt.
Malfunction of L.H.travel perform troubleshooting with engine stopped.
11 control valve (spool) • Check for locked or trapped travel spool in control valve body.
35.80 to 40.70
Malfunction of travel control Travel relief R.H. travel FORWARD hydraulic MPa {365 to 415
valve (pressure pressure relief
12 compensation valve) (R.H. kg/cm2}
travel FORWARD side) a If normal relief pressure is not obtained, pressure compensation valve
may malfunction.
Interchange pressure compensation valves on FORWARD and
REVERSE sides, and check whether failure symptom changes.
Malfunction of travel control a Be ready with engine stopped, then perform troubleshooting with engine
valve (pressure running at full speed.
13 compensation valve) (R.H. 35.80 to 40.70
Travel relief
travel REVERSE side) R.H travel REVERSE hydraulic relief MPa {365 to 415
pressure
kg/cm2}
14 compensation valve) (L.H. 35.80 to 40.70
Travel relief L.H. travel FORWARD hydraulic
travel FORWARD side) MPa {365 to 415
pressure relief kg/cm2}
Travel relief
travel REVERSE side) L.H. travel REVERSE hydraulic relief MPa {365 to 415
pressure
kg/cm2}
PC360LC-10 40-691
40 Troubleshooting
mode)

Connect hoses from L.H. and R.H. travel motors to swivel joint changing
Defective center swivel
16 joint connecting ports with each other, and check whether direction in which
machine deviates changes.
17 Defective travel motor running at full speed.
Leakage from Travel hydraulic relief Max. 30 l /min
travel motor
18 Defective final drive a Check for unusual noise, unusual heat, and metallic powders in drained
oil to make judgment.
40-692 PC360LC-10
40 Troubleshooting
mode)
H-21 Travel speed is too low (PC300-D20-400-A-Z0-A)
Failure • Travel speed is low.

• If failure codes are displayed, perform troubleshooting for them first. (DXE0KA, DXE0KB)
Related • Pump pressure can be checked with monitoring function. (Code: F pump pressure 01100,
information R pump pressure 01101)
• Travel PPC pressure can be checked with monitoring function. (Code: 01882)
• Current to LS-EPC solenoid can be checked with monitoring function. (Code: 01500)
PPC valve R.H. travel control
pressure lever
Malfunction of L.H. travel
2 L.H. travel PPC NEUTRAL 0 MPa {0 kg/cm2}
PPC valve L.H. travel control
pressure lever
Malfunction of self- running at full speed.
3 pressure reducing valve
Control circuit 2.84 to 3.43 MPa
source pressure All control levers in NEUTRAL {29 to 35 kg/cm2}
Approx. 1.5 MPa
4 lever: NEUTRAL
moved
Malfunction of R.H.travel • Check for locked or trapped travel spool in control valve body.
Malfunction of L.H.travel perform troubleshooting with engine stopped.
35.80 to 40.70
Malfunction of travel control Travel relief R.H. travel FORWARD hydraulic MPa {365 to 415
valve (pressure pressure relief
7 compensation valve) (R.H. kg/cm2}
travel FORWARD side) a If normal relief pressure is not obtained, pressure compensation valve
may malfunction.
PC360LC-10 40-693
40 Troubleshooting
mode)
8 compensation valve) (R.H. 35.80 to 40.70
Travel relief
travel REVERSE side) R.H travel REVERSE hydraulic relief MPa {365 to 415
pressure
kg/cm2}
Travel relief L.H. travel FORWARD hydraulic
travel FORWARD side) MPa {365 to 415
Travel relief
travel REVERSE side) L.H. travel REVERSE hydraulic relief MPa {365 to 415
pressure
kg/cm2}
If relief pressure of only one port is below standard value after adjusting
Malfunction of travel control relief valve, suction valve may malfunction.
11 valve (suction valve)
Check suction valve (check valve) for defects and setting of spring.
12 Defective travel motor running at full speed.
Leakage from Travel hydraulic relief Max. 30 l /min
travel motor
40-694 PC360LC-10
40 Troubleshooting
mode)
H-22 Machine is hard to steer or travel power is low (PC300-L18-400-A-Z0-A)
Failure • Machine is not steered well or steering power is low.

• If failure codes are displayed, perform troubleshooting for them first. (DW91KA, DW91KB,
DHS3MA, DXE5KA, DXE5KB, DXE6KA, DXE6KB)
Related • Travel PPC pressure can be checked with monitoring function. (Code: 01882)
information • Current to merge-divider (main) solenoid can be checked with monitoring function. (Code:
08000)
08001)
PPC valve R.H travel control
pressure lever
2 L.H. travel PPC NEUTRAL 0 MPa {0 kg/cm2}
PPC valve L.H. travel control
pressure lever
Malfunction of travel Both levers in
3 junction solenoid valve Travel junction 0 MPa {0 kg/cm2}
Travel control NEUTRAL
solenoid valve
lever When either lever 2.84 to 3.43 MPa
output pressure
is operated {29 to 35 kg/cm2}
• Check for locked or trapped travel junction valve spool in merge-divider
Malfunction of travel valve body.
4 junction valve (spool)
• Remove travel junction valve spool from valve body and check it for
defects and dirt.
relief
0 mA
NEUTRAL
EPC current
800 to 1000 mA
relief
relief
0 mA
NEUTRAL
EPC current
800 to 1000 mA
relief
PC360LC-10 40-695
40 Troubleshooting
mode)

7 divider main spool
8 divider LS spool
Malfunction of R.H. travel • Check for locked or trapped travel spool in control valve body.
Malfunction of L.H. travel perform troubleshooting with engine stopped.
35.80 to 40.70
Travel relief R.H. travel FORWARD hydraulic MPa {365 to 415
pressure relief
Malfunction of travel control kg/cm2}
valve (pressure
11 compensation valve) (R.H. a If normal relief pressure is not obtained, pressure compensation valve
may malfunction.
travel FORWARD side)
a If relief pressures of R.H. travel FORWARD and L.H. travel REVERSE
are same and below standard value, main relief valve of rear pump may
malfunction. Check arm relief pressure additionally.
Malfunction of travel control 35.80 to 40.70
valve (pressure Travel relief
12 compensation valve) (R.H. R.H travel REVERSE hydraulic relief MPa {365 to 415
pressure
kg/cm2}
travel REVERSE side)
If measured values in checks on causes 11 and 12 are same and below
standard value, main relief valve of rear pump may malfunction. Check arm
relief pressure additionally.
valve (pressure Travel relief L.H. travel FORWARD hydraulic
13 compensation valve) (L.H. MPa {365 to 415
travel FORWARD side)
If relief pressures of L.H. travel FORWARD and L.H. travel REVERSE are
same and below standard value, main relief valve of front pump may
malfunction. Check bucket relief pressure additionally.
40-696 PC360LC-10
40 Troubleshooting
mode)

valve (pressure Travel relief
14 compensation valve) (L.H. L.H. travel REVESE hydraulic relief MPa {365 to 415
pressure
kg/cm2}
travel REVERSE side)
If measured values in checks on causes 13 and 14 are same and below
standard value, main relief valve of front pump may malfunction. Check
bucket relief pressure additionally.
If relief pressure of only one port is below standard value after adjusting
Malfunction of travel control relief valve, suction valve may malfunction.
15 valve (suction valve)
Check suction valve (check valve) for defects and setting of spring.
Connect hoses from L.H. and R.H. travel motors to swivel joint changing
Defective center swivel
16 joint connecting ports with each other, and check whether direction in which
machine deviates changes.
If relief pressures of both R.H. travel FORWARD and REVERSE are
unusual in checks on causes 11 and 12 respectively, respective safety
Defective R.H. travel motor valves may be defective.
17 (safety valve)
Interchange safety valves of L.H. and R.H. travel motors, and check
If relief pressures of both L.H. travel FORWARD and REVERSE are
unusual in checks on causes 13 and 14 respectively, respective safety
Defective L.H. travel motor valves may be defective.
18 (safety valve)
If pressure compensation valves are found to be normal in checks on
Defective R.H. travel motor causes 11 and 12, check valves may malfunction.
19 (safety valve)
Interchange check valves on FORWARD and REVERSE sides of same
travel motor, and check whether failure symptom changes.
If pressure compensation valves are found to be normal in checks on
Defective L.H. travel motor causes 13 and 14, check valves may malfunction.
20 (check valve)
21 Defective R.H. travel motor running at full speed.
Leakage from
R.H. travel relief Max. 30 l /min
travel motor
22 Defective L.H. travel motor running at full speed.
Leakage from L.H. travel hydraulic relief Max. 30 l /min
travel motor
PC360LC-10 40-697
40 Troubleshooting
mode)
H-23 Travel speed does not change, or travel speed is too low or
high (PC300-BQ4-400-A-Z0-A)
Failure • Travel speed does not change or travel speed is too low or high.
• If failure codes are displayed, perform troubleshooting for them first.(DW43KA, DW43KB)
Related • Current to LS-EPC solenoid can be checked with monitoring function. (Code: 01500)
information • Signal (ON/OFF) of travel speed selector solenoid can be checked with monitoring
function. (Code: 02300)
Travel control 580 mA
lever: Finely Travel speed: Lo
moved (* Reference)
Travel control
LS-EPC current Travel speed: Mi
lever: Finely 740 mA
value
moved
Travel control
Malfunction of LS-EPC lever: Finely Travel speed: Hi 0 mA
1
valve moved
Approx. 1.5 MPa
Travel control Travel speed: Lo {Approx. 15 kg/
LS-EPC output lever: NEUTRAL cm2}
pressure Travel control
moved
Malfunction of travel speed Travel control Travel speed: Lo 0 MPa {0 kg/cm2}
2 lever: NEUTRAL
selector solenoid valve Solenoid valve
outlet pressure Travel control 2.84 to 3.43 MPa
lever: Finely Travel speed: Hi
{29 to 35 kg/cm2}
moved
Malfunction of travel motor If no failure is found by checks on causes 1 and 2, speed switching portion
3 (speed switching portion) of travel motor may malfunction.
* : Travel speed of Lo setting can be adjusted by using adjustment function of machine monitor. If it is
changed from default value, LS-EPC current value changes slightly.
40-698 PC360LC-10
40 Troubleshooting
mode)
H-24 One of tracks does not run (PC300-BG1-400-A-Z0-A)
Failure • One of tracks does not run..

Related • Travel PPC pressure can be checked with monitoring function. (Code: 01882)
information • Pump pressure can be checked with monitoring function. (Code: F pump pressure 01100,
R pump pressure 01101)
Malfunction of R.H. travel R.H travel control
1 NEUTRAL 0 MPa {0 kg/cm2}
PPC valve PPC valve output lever
pressure R.H travel control FORWARD and 2.84 to 3.43 MPa
lever REVERSE {29 to 35 kg/cm2}
Malfunction of L.H. travel L.H. travel control
PPC valve PPC valve output lever
pressure L.H. travel control FORWARD and 2.84 to 3.43 MPa
lever REVERSE {29 to 35 kg/cm2}
If no failure is found by check on cause 1 and one track does not run when
3 control valve (spool) travel control lever is operated with pump pressure at approx. 4 MPa,
check whether spool is locked near NEUTRAL position.
If no failure is found by check on cause 2 and one track does not run when
4 control valve (spool) travel control lever is operated with pump pressure at approx. 4 MPa,
check whether spool is locked near NEUTRAL position.
When R.H. travel control lever is operated, if R.H. track does not run
5 control valve (suction because of low pump pressure, check suction valve.
valve)
When L.H. travel control lever is operated, if L.H. track does not run
6 control valve (suction because of low pump pressure, check suction valve.
valve)
35.80 to 40.70
Travel relief R.H. travel FORWARD and MPa {365 to 415
Defective R.H. travel motor pressure hydraulic relief REVERSE
7 (safety valve) kg/cm2}
If relief pressures of travel FORWARD and REVERSE are unusual to the
same degree, sealing of safety valve may be defective.
35.80 to 40.70
Travel relief L.H. travel FORWARD and MPa {365 to 415
Defective L.H. travel motor pressure hydraulic relief REVERSE
If relief pressures of travel FORWARD and REVERSE are unusual to the
same degree, sealing of safety valve may be defective.
If safety valve is found to be normal in checks on cause 7, sealing of check
Defective R.H. travel motor valve may be defective.
9 (check valve)
PC360LC-10 40-699
40 Troubleshooting
mode)

If safety valve is found to be normal in checks on cause 8, sealing of check
Defective L.H. travel motor valve may be defective.
10 (check valve)
Defective travel motor When running R.H. track idle off ground, if R.H. track does not run with R.
11 (parking brake) H. travel circuit pressure reaching relief pressure, travel parking brake may
malfunction.
Defective L.H. travel motor When running L.H. track idle off ground, if L.H. track does not run with L.H.
12 (parking brake) travel circuit pressure reaching relief pressure, travel parking brake may
malfunction.
13 Defective R.H. travel motor running at full speed.
Leakage from R. R.H travel control R.H travel
hydraulic relief Max. 30 l /min
H. travel motor lever
14 Defective L.H. travel motor running at full speed.
Leakage from L. L.H. travel control L.H. travel
hydraulic relief Max. 30 l /min
H. travel motor lever
40-700 PC360LC-10
40 Troubleshooting
mode)
H-25 Upper structure does not swing in both right and left
directions (PC300-L41-400-A-Z0-A)
Failure • Upper structure does not swing in both right and left directions.
Related • If failure codes are displayed, perform troubleshooting for them first. (DW45KA, DW45KB)
Malfunction of swing PPC Swing control
valve Swing PPC valve lever
output pressure Swing control Left swing and 2.84 to 3.43 MPa
lever Right swing {29 to 35 kg/cm2}
Malfunction of swing running at full speed.
2 holding brake solenoid Swing control 0 MPa {0 kg/cm2}
Swing holding NEUTRAL
valve lever
brake solenoid
Swing control Left swing and 2.84 to 3.43 MPa
output pressure
When no failure is found by check on cause 1, if upper structure does not
Malfunction of swing motor swing with swing circuit pressure reaching relief pressure, swing holding
3 (swing holding brake) brake may malfunction.
(Check pump pressure by using monitoring function to make judgment.)
If no failure is found by checks on causes 1 and 2 and upper structure does
Malfunction of swing
4 control valve (spool) not swing when swing control lever is operated with pump pressure at
approx. 4 MPa, check whether spool is locked near NEUTRAL position.
28.42 to 32.85
Swing relief Swing lock Swing hydraulic MPa {285 to 335
Defective swing motor pressure switch: ON. relief
If relief pressures of left swing and right swing are same and below
standard value, sealing of safety valve may be defective.
Safety valve has 2-stage relief function, however, set pressures for Hi and
Lo settings are same (relief flow rate differs).
6 Defective swing motor running at full speed.
Leakage from Swing lock Swing hydraulic
swing motor Max. 11 l /min
switch: ON. relief
Swing machinery may have internal failure.
7 Defective swing machinery a Check for unusual noise, unusual heat, and metallic powders in drained
PC360LC-10 40-701
40 Troubleshooting
mode)
H-26 Upper structure does not swing in only one direction. (PC300-L42-400-A-Z0-A)
Failure • Upper structure does not swing in only one direction.

Related • Swing PPC pressure can be checked with monitoring function. (Code: Left swing 09001,
information Right swing 09002)
valve Swing PPC valve lever
output pressure Swing control Left swing and 2.84 to 3.43 MPa
If no failure is found by check on cause 1 and upper structure does not
2 control valve (spool) swing when swing control lever is operated with pump pressure at approx.
4 MPa, check whether spool is locked near NEUTRAL position.
Interchange shuttle valves on left and right swing sides of swing motor, and
Defective seating of swing check whether failure symptom changes to make judgment.
3 motor (shuttle valve)
When removing valve, check it for lock and defects.
Interchange check valves on left and right swing sides of swing motor, and
4 motor (check valve)
40-702 PC360LC-10
40 Troubleshooting
mode)
H-27 Swing acceleration or swing speed is low in both directions (right

and left) (PC300-L44-400-A-Z0-A)
Failure • Swing acceleration or swing speed is low in both directions (right and left).
Related • If failure codes are displayed, perform troubleshooting for them first. (DW45KA, DW45KB)
Malfunction of swing Swing spool may malfunction.
1 control valve (spool) Check spool for getting trapped and defects.
Remove LS shuttle valve block of R.H. travel control valve and clean check
valve portion. Check shuttle valve for defects.
valve)
Remove LS shuttle valve block of L.H. travel control valve and clean check
valve portion.
valve)
Malfunction of boom
Remove LS shuttle valve boom control valve and clean check valve
portion.
valve)
Malfunction of arm control Remove LS shuttle valve block of arm control valve and clean check valve
5 valve (LS shuttle valve) portion.
Remove LS shuttle valve block of bucket control valve and clean check
valve portion.
valve)
Malfunction of service Remove LS shuttle valve block of service valve and clean check valve
7 valve (LS shuttle valve) portion.
valve lever
brake solenoid
output pressure
Malfunction of swing motor If no failure is found by check on cause 8, swing holding brake may
9 (swing holding brake) malfunction (dragging).
28.42 to 32.85
If normal pressure is not obtained after adjustment, sealing of safety valve
may be defective.
switch: ON. relief
PC360LC-10 40-703
40 Troubleshooting
mode)
H-28 Swing acceleration performance is poor or swing speed is slow in

only one direction (PC300-L45-400-A-Z0-A)
Failure • Swing acceleration performance is poor or swing speed is slow in only one direction.
valve PPC valve output lever
pressure Swing control Left swing and 2.84 to 3.43 MPa
If no failure is found by check on cause 1 and upper structure does not
2 swing when swing control lever is operated with pump pressure at approx.
control valve (spool)
4 MPa, check whether spool is locked near NEUTRAL position.
Malfunction of swing Pressure compensation valve on right swing side of swing control valve
control valve (pressure may malfunction.
3 compensation valve on Interchange pressure compensation valves on left and right swing sides
right swing side) and check whether failure symptom changes to make judgment.
Malfunction of swing Pressure compensation valve on left swing side of swing control valve may
control valve (pressure malfunction.
4 compensation valve on left Interchange pressure compensation valves on left and right swing sides
swing side) and check whether failure symptom changes to make judgment.
Interchange suction valves on left and right swing sides of swing motor,
Defective seating of swing and check whether failure symptom changes to make judgment.
5 motor (suction valve)
40-704 PC360LC-10
40 Troubleshooting
mode)
H-29 Upper structure overruns remarkably when it stops swinging in

both directions (right and left) (PC300-L47-400-A-Z0-A)
• Upper structure overruns remarkably when it stops swinging in both directions (right and
Failure left).
Related • If failure codes are displayed, perform troubleshooting for them first. (DWK0KA, DWK0KB)
28.42 to 32.85
Defective swing motor pressure switch: ON relief
may be defective.
switch: ON relief
PC360LC-10 40-705
40 Troubleshooting
mode)
H-30 Upper structure overruns excessively when it stops swinging in

only one direction (PC300-L48-400-A-Z0-A)
Failure • Upper structure overruns excessively when it stops swinging in only one direction.
Slow return valve for right swing PPC may malfunction. Interchange slow
return valves for left and right swings, and check whether failure symptom
Clogged slow return valve changes to make judgment.
2 for right swing
When removing slow return valve, check slow return valve strainer for
clogging.
Slow return valve for left swing PPC may malfunction. Interchange slow
return valves for left and right swings, and check whether failure symptom
Clogged slow return valve changes to make judgment.
3 for left swing PPC
When removing slow return valve, check slow return valve strainer for
clogging.
Malfunction of swing Swing spool may malfunction.
Check spool for getting trapped and defects.
Defective sealing of swing and check whether failure symptom changes to make judgment.
40-706 PC360LC-10
40 Troubleshooting
mode)
H-31 Shock is large when upper structure stops swinging (PC300-L49-400-A-Z0-A)
Failure • Shock is large when upper structure stops swinging.

Slow return valve for right swing PPC may malfunction. Interchange slow
Malfunction of slow return
2 return valves for left and right swings, and check whether failure symptom
valve for right swing PPC
changes to make judgment.
Slow return valve for left swing PPC may malfunction. Interchange slow
Malfunction of slow return
3 return valves for left and right swings, and check whether failure symptom
valve for left swing PPC
changes to make judgment.
Malfunction of swing motor Reverse prevention valve of swing motor may malfunction.
4 (reverse prevention valve) Check for locked or almost trapped spool and setting of spring.
PC360LC-10 40-707
40 Troubleshooting
mode)
H-32 Large unusual noise is heard when upper structure stops

swinging (PC300-BAB-400-A-Z0-A)
Failure • Large unusual noise is heard when upper structure stops swinging.
information • If failure codes are displayed, perform troubleshooting for them first. (DWK2KA, DWK2KB)
Malfunction of solenoid running at full speed.
1 valve of variable back Output pressure Swing control 0 MPa {0 kg/cm2}
NEUTRAL
pressure valve of solenoid valve lever
of variable back Swing control Left swing and 2.84 to 3.43 MPa
pressure valve lever Right swing {29 to 35 kg/cm2}
If no failure is found by check on cause 1, back pressure valve of control
Malfunction of back valve may malfunction.
2 pressure valve Check for locked or almost trapped valve, defects of valve, and setting of
spring.
Safety valve of swing motor may malfunction.
Malfunction of swing motor
3 (safety valve) If normal pressure is not obtained after adjustment, safety valve may have
internal failure.
40-708 PC360LC-10
40 Troubleshooting
mode)
H-33 When swing holding brake is applied, hydraulic drift of swing is

large (PC300-MS6-400-A-Z0-A)
Failure • Hydraulic drift of swing is large (when swing holding brake is applied).
• When swing lock switch is set to ON position or swing brake cancel switch is set to
Related NORMAL position, swing brake is applied and swing system is locked by disc brake.
information • Perform all troubleshooting with working mode set in P mode.
• If failure codes are displayed, perform troubleshooting for them first. (DW45KA, DW45KB)
valve lever
brake solenoid
output pressure
Malfunction of swing motor If no failure is found by check on cause (1), swing holding brake may
2 (swing holding brake)
malfunction.
switch: ON. relief
PC360LC-10 40-709
40 Troubleshooting
mode)
H-34 When swing holding brake is released, hydraulic drift of swing is

large (PC300-MS7-400-A-Z0-A)
Failure • Hydraulic drift of swing is large (when swing holding brake is released).
Related • Pump pressure can be checked with monitoring function. (Code: F pump pressure 01100,
information R pump pressure 01101)
1 control valve (spool) Spool of swing control valve may malfunction. Check for locked spool.
Malfunction of swing Pressure compensation valve on right swing side of swing control valve
control valve (pressure may malfunction.
2 compensation valve on
Interchange pressure compensation valves on left and right swing sides
right swing side) and check whether failure symptom changes to make judgment.
Malfunction of swing Pressure compensation valve on left swing side of swing control valve may
control valve (pressure malfunction.
3 compensation valve on left
Interchange pressure compensation valves on left and right swing sides
swing side) and check whether failure symptom changes to make judgment.
27.93 to 32.85
may be defective.
When removing valve, check it for lock valve and defects.
Malfunction of swing motor Reverse prevention valve of swing motor may malfunction.
7 (reverse prevention valve) Check for locked or almost trapped spool and setting of spring.
40-710 PC360LC-10
40 Troubleshooting
mode)
H-35 When additional attachment is installed, attachment circuit is not

switched (PC300-HBD-400-A-Z1-A)
Failure • When additional attachment is installed, attachment circuit is not switched.
• For machines with provision for attachment, attachment circuit switches as follows
depending on selected working mode.
1. When ATT mode is selected: Attachment circuit switches to 2-way circuit and safety
valve is set to low-pressure setting.
2. Wnen B mode is selected: Attachment circuit switches to 1-way circuit and safety valve
Related is set to high-pressure setting.
information
a Note that set pressure of safety valve switches only on port B side, and that on port A
side remains at low-pressure setting without switching.
• If failure codes are displayed, perform troubleshooting for them first. (DWA2KA, DWA2KB)
Malfunction of ATT return ATT return Working mode ATT mode 0 MPa {0 kg/cm2}
1
selector solenoid valve selector solenoid
valve output 2.84 to 3.43 MPa
Working mode B mode
pressure {29 to 35 kg/cm2}
If no failure is found by check on cause (1), ATT return selector solenoid
Malfunction of ATT return valve may malfunction.
2
selector solenoid valve Check for locked or almost trapped valve, defects of valve, and setting of
spring.
Defective adjustment or Safety valve of service valve may malfunction.
3 malfunction of service If normal pressure is not obtained after adjustment, safety valve may have
valve (safety valve) internal failure.
PC360LC-10 40-711
40 Troubleshooting
mode)
H-36 Oil flow in attachment circuit cannot be controlled (PC300-HBE-400-A-Z0-A)
Failure • Oil flow in attachment circuit cannot be controlled.

• For machines with provision for attachment, oil flow rate of attachment circuit varies
depending on selected working mode.
Related • Procedure for oil flow rate adjustment differs between working modes, ATT mode and B
information mode. For details, see Operation and Maintenance Manual.
• If failure codes are displayed, perform troubleshooting for them first. (DXE4KA, DXE4KB)
Attachment
ATT oil flow control pedal
adjustment EPC Pressure
valve output Attachment corresponding to
Malfunction of ATT oil flow pressure Depressed
1 adjustment EPC valve control pedal selected oil flow
setting
a If output pressure of EPC valve is 0 MPa, check "Service solenoid
current" with monitoring function. (Code: 01700)
If current value is 0.3 to 0.91 A, EPC valve may be defective.
Check that output pressure changes according to selected oil flow
setting.
Attachment
Malfunction of service PPC control pedal
2 Service PPC
valve valve output Pressure
pressure Attachment corresponding to
Depressed
control pedal selected oil flow
setting
• Check that output pressure changes according to pedal stroke.
40-712 PC360LC-10
40 Troubleshooting
Troubleshooting of engine (S-mode)
Troubleshooting of engine (S-mode) (ALL-3840-001-A-03-A)
Information contained in troubleshooting table (S mode) (PC300-5170-010-A-00-A)
(Rev. 2011/04 114T4)
a The following information is summarized in the troubleshooting table. Before carrying out troubleshooting,
Failure Description of failure code
Related Information related to detected failure or troubleshooting
information
No. Cause Detail of work, remarks Remedy
1
2 Probable causes for trouble <Contents of description>
(Given numbers are • Remedy to
3 reference numbers, which do • Check item to judge probable cause eliminate probable
4 not indicate priority) • Remarks on judgment cause of trouble
5
2. Cooling plate
3. Check valve
4. Fuel feed pump
a Check valve (3) described in the text is installed on cooling plate (2).
a Fuel feed pump (4) is on the back side of cooling plate (2) to which engine controller (1) is installed.
PC360LC-10 40-713
40 Troubleshooting
S-1 Engine does not crank when starting switch is turned to START
position (D65-A26-400-A-Z0-A)
Failure Engine does not crank when starting switch is turned to START position.
Related • See E mode (E-1) for troubleshooting of electrical system.
information • If any failure code is displayed, perform troubleshooting for that code first.
No. Cause Point to check, remarks Remedy
Defective wiring harness in • When starting switch is turned to START Perform
1 starting circuit position, starting motor pinion is not pushed troubleshooting for E-1
out and take remedies.
• Grating noise is heard from starting motor
pinion.
(When starting switch is turned to START
position, starting motor pinion is pushed
out.)
• Starting motor pinion disengages during
operation.
position, starting motor pinion is pushed Perform
2 Defective starting motor troubleshooting for E-1
out.)
• Rattling noise is heard and starting motor and take remedies.
does not rotate.
position, starting motor pinion is pushed
out.)
(Reference: Rattling noise is caused when
starting motor pinion is repeatedly pushed
out and pulled in.)
• If grating noise is heard from starting motor
3 Broken flywheel ring gear pinion and starting motor does not rotate, Replace if damaged
visually check flywheel ring gear.
• Remove EGR cooler outlet gas piping and
check whether coolant containing
Cracked EGR cooler COOLANT flows out. Replace EGR cooler
4 (Reference: coolant in and drain water from
exhaust gas) a Water in exhaust gas can be normally engine cylinders
condensed, so check that condensate is
coolant or not.
40-714 PC360LC-10
40 Troubleshooting
S-2 The engine cranks but exhaust smoke does not come out (D65-A27-400-A-Z0-A)
Failure Engine cranks but no exhaust smoke comes out

Related • If any failure code is displayed, carry out troubleshooting for it first.
information
No. Cause Check item, remark Remedy
• When fuel tank is inspected, it is found to be
1 Insufficient fuel in tank empty Add fuel
Flush air breather hole
Air breather hole in fuel tank
2 cap is clogged • Air breather hole in fuel tank cap is clogged in fuel tank cap and
clean surrounding area
• Check used hours of fuel filter. If used
Replace fuel filter
3 Clogged fuel filter element beyond specified hours, fuel filter element
may be clogged element
• Rust and water are found when fuel tank is Replace fuel
4 Foreign material in fuel
drained
• Air is discharged when the air is bled from Air bleeding
the fuel system
5 Air in fuel piping system (Reference: See Testing and adjusting, Correct or replace fuel
"Bleeding air from fuel system") piping
• Fuel is leaking from fuel piping
Leakage from fuel piping Correct or replace fuel
6 system (Reference: See Testing and adjusting,
piping related parts
"Checking fuel system for leakage".)
• Excessive injector return rate (See Testing
Fuel leakage from injector and adjusting, "Measuring fuel delivery, Tighten or replace inlet
7
and inlet connector return and leakage".) connector
• See Testing and adjusting, "Measuring fuel Replace supply pump
8 Defective supply pump delivery, return and leakage". and pressure limiter
Sticking of check valve on Clean or replace check
9 cooling plate • Sticking of check valve
valve
Replace fuel feed
10 Defective fuel feed pump • No fuel from fuel feed pump
pump
• Common rail pressure does not go down
even after pressure is checked with Loosen injection piping
monitoring function and then the engine is and high pressure
Improper bleeding of common
11 rail or injection piping stopped. (Code: 36400 Common rail piping mounting nuts
pressure) on common rail and
(Pressure will not decrease if air still bleed air
remains.)
PC360LC-10 40-715
40 Troubleshooting
S-3 Fuel is being injected but engine does not start (incomplete
combustion: engine cranks but does not start) (D65-A28-400-A-Z0-A)
Fuel is being injected but engine does not start (incomplete combustion: engine cranks but
Failure does not start)
information
• Specific gravity of electrolyte and voltage of Add battery electrolyte
1 Defective battery
battery are low. and charge
3 • Air breather hole in fuel tank cap is clogged in fuel tank cap and
cap is clogged
Clogged fuel filter element beyond specified hours, fuel filter element Replace fuel filter
4
Foreign material in fuel • Rust and water are found when fuel tank is Replace fuel
5
drained
• Air is discharged when the air is bled from Bleed air
the fuel system
6 Air in fuel piping system
(Reference: See Testing and adjusting, Correct or replace fuel
7 (Reference: See Testing and adjusting,
system piping related parts
8
9 • Sticking of check valve
cooling plate valve
Replace fuel feed
10 Defective fuel feed pump • No fuel from fuel feed pump
pump
Testing and adjusting
11 Clogged air cleaner element • Air cleaner dust indicator in caution level
air cleaner element
• Intake air heater mount does not warm up
during preheating operation.
• When engine is preheated or when Replace intake air
12 Defective intake air heater
temperature is low, preheating monitor does heater
not indicate properly.
• Check valve clearance
(Reference: See Testing and adjusting,
Worn valve or rocker arm, "Measuring and adjusting valve clearance".) Replace valve or
13
etc. • When engine is rotated, abnormal sound is rocker arm
generated around cylinder head.
• Measuring compression pressure
Replace piston ring or
14 Defective piston ring (Reference: See Testing and adjusting,
piston
"Measuring compression pressure".)
Defective injector • Engine speed does not change even when
running engine with some cylinder cutout.
15 (clogged injector, defective Replace injector
injection) "Handling cylinder cutout mode operation".)
40-716 PC360LC-10
40 Troubleshooting
S-4 Startability is poor (D65-A10-400-A-Z0-A)
Failure Starting performance is poor.

• If any failure code is displayed, carry out troubleshooting for it first.
Related • Common rail fuel injection system (CRI) controls the fuel injection timing electrically.
information Therefore, there are cases where the engine does not start before the crankshaft makes
two rotations maximum after starting operation. This is not an abnormal state, however.
• Specific gravity of electrolyte and voltage of Add battery electrolyte
1 Defective battery
battery are low. and charge
• Fuel other than specified one is used.
• Fuel used does not accord with the ambient
temperature Use proper fuel
Improper fuel used (Reference: Starts when warm but does not specified in Operation
3
easily start when cold.) and Maintenance
• Deposited wax (milky) is found in clear bowl Manual
of fuel pre-filter.
cap is clogged
5
6
drained
the fuel system
9
10 Defective supply pump delivery, return and leakage". and pressure limiter
11 cooling plate • Sticking of check valve
valve
Check, clean air
cleaner element
• Intake air heater mount does not warm up
during preheating operation.
• When engine is preheated or when Replace intake air
13 Defective intake air heater
temperature is low, preheating monitor does heater
not indicate properly.
• Remove EGR cooler outlet gas piping and
check if coolant containing COOLANT flows
Cracked EGR cooler out Replace EGR cooler
14 (Reference: coolant in and drain water from
exhaust gas) a Water can normally be condensed in the engine cylinders
exhaust gas, so make sure the water is
coolant or not.
PC360LC-10 40-717
40 Troubleshooting

• When exhaust manifold is touched
immediately after starting engine,
temperature of some cylinders is low
15 Defective injector • Engine speed does not change even when Replace injector
"Handling cylinder cutout mode operation".)
• Measure the compression pressure (see
standard value table).
Defective valve or contact of "Measuring compression pressure".) Correct or replace
16
valve with valve seat • Test the valve clearances valve or valve seat
"Measuring and adjusting valve clearance".)
• Open the exhaust gas color measuring hole
before the KDPF and check the color of the
exhaust gas.
"Testing exhaust gas color".) Replace piston ring or
17 Defective piston ring • Measure the compression pressure (see piston
• Check piston rings and piston ring grooves
40-718 PC360LC-10
40 Troubleshooting
S-5 Engine does not pick up smoothly (D65-A30-400-A-Z0-A)
Failure Engine does not pick up smoothly

information
cap is clogged
3
4
drained
the fuel system
7
8 Defective supply pump
delivery, return and leakage". and pressure limiter
cooling plate valve
• When error is not cleared even after KCCV
filter is replaced and crankcase pressure
high error (failure code: CA555) is still Perform the following
10 Crankcase pressure too high displayed, the blowby pressure may be high checks on cause 10
(see Testing and adjusting, "Measuring and below
blowby pressure"). At this time, KVGT may
be seized or damaged.
• Unusual noise is heard from KVGT
• Check if KVGT shaft rotates
12 KVGT seized or broken Replace KVGT
(Move KVGT vanes with hand in axial and
radial directions to judge)
• When engine is cranked, unusual noise is
heard around cylinder head
13 Incorrect valve clearance • Check valve clearance Adjust valve clearance
PC360LC-10 40-719
40 Troubleshooting

Defective contact of valve "Measuring compression pressure".) Correct or replace
14
with valve seat • Test the valve clearances valve or valve seat
exhaust gas.
15 Defective piston ring • Measure the compression pressure (see piston
40-720 PC360LC-10
40 Troubleshooting
S-6 Engine stops during operation (D65-AF0-400-A-Z0-A)
Failure Engine stops during operation

information
cap is clogged
3
4
drained
the fuel system
7
cooling plate valve
Defective intake air hose
• Visually check air intake hose for breakage Replace air intake
10 (between air cleaner and
hose
KVGT inlet)
• Check air intake manifold for internal Replace air intake
11 Defective air intake manifold breakage manifold
Defective boost piping and
connections Correct or replace
12 • Air comes out from boost piping
(From KVGT outlet to air boost piping
intake manifold)
Defective exhaust pipes • Check exhaust pipes for damage and
exhaust gas leakage
13 (from exhaust manifold to Replace exhaust pipes
(Check heat insulation cover and soot on
KDPF inlet) heat insulation plate)
• Check valve and rocker arm
Replace valve or
14 Damaged valve or rocker arm (Unusual noise is heard and engine stops
suddenly.) rocker arm
• Metal particles are found in oil drained from
oil pan
• Remove oil pan and check piston and
Broken or seized piston and Replace piston and
15 connecting rod connecting rod
connecting rod
(Reference: Unusual noise is heard and
engine stops suddenly, or stops due to
overheat.)
• Metal particles are found in oil drained from
Broken or seized crankshaft oil pan Replace crankshaft
16 main bearing • Remove oil pan and check crankshaft main main bearing
bearing
PC360LC-10 40-721
40 Troubleshooting

• Check wiring in engine controller power
Correct wiring in
Defective wiring in engine supply
17 controller power supply engine controller
(Reference: See Troubleshooting, "Failure
power supply
code [CA343]".)
Defective starting switch Diagnosis and remedy
18 wiring • Check starting switch wiring
by E-1
• See H-mode, "H-2 Engine speed lowers Diagnosis and remedy
19 Defective hydraulic system significantly on engine stalls". by H-2
40-722 PC360LC-10
40 Troubleshooting
S-7 Engine runs rough or is unstable (D65-A40-400-A-Z0-A)
Failure Engine runs rough or is unstable

information
cap is clogged
3
4
drained
the fuel system
7
• Check boost system (between KVGT outlet Correct or replace
Fuel leakage from boost
8 and aftercooler, aftercooler and air intake boost piping related
system
manifold) for fuel leakage parts
cooling plate valve
• Replace sensor and check if problem is
Defective mass air flow and corrected Replace mass air flow
10 temperature sensor (Failure code may not be issued if the and temperature
sensor is covered with dust.) sensor
• Check connecting part of connectors Check connecting part
Defective KVGT speed • Check KVGT speed sensor after
11 or replace KVGT speed
sensor replacement sensor
PC360LC-10 40-723
40 Troubleshooting
S-8 Engine lacks power (D65-A60-400-A-Z0-A)
Failure Engine lack output (or lacks power)

information
cap is clogged
3
4
drained
the fuel system
7
cooling plate valve
Check, clean air
cleaner element
• Check air cleaner and rectifying wire net for Correct or replace air
11 Defective air cleaner
deformation cleaner
Defective air intake hose
• Visually check air intake hose for breakage Replace air intake
12 (between air cleaner and
hose
KVGT inlet)
• Check air intake manifold for internal Replace air intake
13 Defective air intake manifold breakage manifold
14 • Air flows out from boost piping
(From KVGT outlet to air boost piping
intake manifold)
Defective mounting of boost • Air leakage from mounting part of boost Correct boost pressure
15 pressure sensor pressure sensor sensor mounting
Defective exhaust pipes • Check exhaust pipes for damage and
exhaust gas leakage
16 (from exhaust manifold to Replace exhaust pipes
(Check heat insulation cover and soot on
KDPF inlet) heat insulation plate)
17 Gas leakage from EGR piping • Gas leaks from EGR piping Replace EGR piping
Check intake and exhaust
system • Measure boost pressure
Correct and replace
18 (between KVGT outlet and air (Reference: See Testing and adjusting,
the troubled part
intake manifold, air intake "Measuring boost pressure".)
manifold and KDPF inlet)
40-724 PC360LC-10
40 Troubleshooting

• Unusual noise is heard from KVGT
• Check if KVGT shaft rotates
19 KVGT seized or broken Replace KVGT
• Open the exhaust color inspection hole in
front of KDPF, check the exhaust gas (refer
Excessive soot accumulation standard value table) Clean or replace KDPF
20
in KDPF (Reference: See Testing and adjusting,
"Testing exhaust gas color".)
• KDPF clogging - check exhaust pressure Clean or replace KDPF
21 Defective KDPF
before KDPF
heard around cylinder head
22 Incorrect valve clearance • Check valve clearance Adjust valve clearance
Defective contact of valve "Measuring compression pressure".) Correct or replace
24
with valve seat • Test the valve clearances valve or valve seat
exhaust gas.
25 Defective piston ring
• Measure the compression pressure (see piston
PC360LC-10 40-725
40 Troubleshooting
S-9 KDPF gets clogged in a short time (D65-AH5-400-A-Z0-A)
Failure Exhaust smoke is black (KDPF gets clogged in a short time)

Related • If any failure code is displayed, perform troubleshooting for that code first.
information
Use proper fuel
Improper fuel used • Fuel other than specified one is used. specified in Operation
1
and Maintenance
Manual.
Foreign material in fuel • Rust and water are found in fuel drained Replace fuel.
2
from fuel tank.
• Check air cleaner and rectifying wire net for Correct or replace air
3 Defective air cleaner
deformation. cleaner.
Defective exhaust gas piping • Check exhaust gas piping for damage and
exhaust gas leakage. Replace exhaust gas
4 (Between exhaust manifold (Check soot on heat insulation cover and piping.
and KDPF inlet) heat insulation plate.)
Defective installation of boost • Air leakage from installed position of boost Correct installation of
5 pressure sensor pressure sensor boost pressure sensor.
6 • Air leaks from boost piping.
(Between KVGT outlet and air boost piping.
intake manifold)
• KDPF is clogged. Check back pressure at Clean or replace
7 Defective KDPF location just upstream of KDPF. KDPF.
8 Gas leakage from EGR piping • Gas leaks from EGR piping. Replace EGR piping.
• Unusual noise is heard from KVGT.
• Check whether KVGT shaft rotates.
9 Seized or broken KVGT Replace KVGT.
radial directions to make judgement.)
• Some cylinder is found to be cool when
exhaust manifolds are touched by hand
immediately after engine is started.
• When engine is run in cylinder cutout mode
10 Defective injector Replace injector.
with some cylinder cut out, engine speed
does not change.
• Measured fuel return rate is excessive.
Correct or replace fuel
11 Defective fuel return piping "Measuring fuel delivery, return and
return piping.
leakage".)
• Check fuel return piping for clogging.
• Replace sensor and check whether
Defective mass air flow and symptom disappears. Replace mass air flow
12 temperature sensor (Failure code may not be generated if and temperature
sensor is covered with dust.) sensor.
heard from around cylinder head.
13 Incorrect valve clearance • Check valve clearance. Adjust valve clearance.
"Testing and adjusting valve clearance".)
40-726 PC360LC-10
40 Troubleshooting

• Measure compression pressure (see
Standard value table).
(Reference: See Testing and adjusting, Correct contact
Defective contact between "Testing compression pressure".) between valve and
14
valve and valve seat • Check valve clearance. valve seat or replace
(Reference: See Testing and adjusting, them.
• Open exhaust color inspection hole that is
just upstream of KDPF, and check exhaust
gas.
"Testing exhaust color".) Replace piston ring or
15 Defective piston ring • Measure compression pressure (see piston.
"Testing compression pressure".)
• Check piston ring and piston ring groove.
PC360LC-10 40-727
40 Troubleshooting
S-10 Engine oil consumption is excessive (PC400-B10-400-A-Z0-A)
Failure Engine oil consumption is excessive

Related information • If any failure code is displayed, carry out troubleshooting for it first.
Dust sucked in from intake • When intake piping between air cleaner Clean or replace
1 system and engine is removed, dust is found intake piping
inside.
• Measured blowby pressure exceeds
standard value.
• Blow-by pressure is still high after KCCV
filter element is replaced Replace or correct
2 Broken or worn piston ring
• Measure the compression pressure (see piston ring
standard values table).
Oil leakage from KCCV oil • Check for oil leaks from KCCV oil return Correct or replace oil
3 return piping piping piping
External leakage of oil from
4 engine • Check for oil leaks Correct oil leaks
Oil leakage from oil filter Reinstall or replace oil

5 • Check for oil leaks from oil filter
filter
Correct or replace oil
6 Oil leakage from oil piping • Check for oil leaks from oil piping
piping
7 Oil leakage from oil drain plug • Check for oil leaks from oil drain plug Retighten oil drain plug
Correct or replace oil
8 Oil leakage from oil pan • Check for oil leaks from oil pan
pan
Correct or replace
9 Oil leakage from cylinder head • Check for oil leaks from cylinder head
cylinder head
• Oil level in clutch chamber or damper Correct or replace rear
10 Worn or damaged rear oil seal
chamber on machine is low. oil seal
• KVGT blower inlet and outlet, and turbine
outlet are dirty with oil.
11 Oil leakage from KVGT • Check if KVGT shaft rotates Replace KVGT
• Oil in coolant
• Remove oil cooler and check for external oil
12 Oil leakage from oil cooler leaks Replace oil cooler
• Check for leaks by applying air pressure to
oil cooler
Oil leakage from EGR valve • When EGR valve is removed, outlet port is
13 Replace EGR valve
stem found to be dirty with oil.
• Check valve guide and stem seal
• Remove cylinder head. Check inside
Worn or damaged valve guide, diameter of guide, and check stem seal for Replace valve guide
14
stem seal damages. and stem seal
(Reference: See "Maintenance standard".)
40-728 PC360LC-10
40 Troubleshooting
S-11 Engine oil becomes contaminated early (PC400-B20-400-A-Z0-A)
Failure Engine oil becomes contaminated quickly.

information
Use proper fuel
1
and Maintenance
Manual.
Use proper oil
Improper oil used • Oil other than specified one is used. specified in Operation
2
and Maintenance
Manual.
• Check exhaust gas color at location just Perform
Black exhaust gas color
upstream of KDPF. troubleshooting for "S-
3 checked at location just
(Reference: See Testing and adjusting, 9 Exhaust gas is
upstream of KDPF
"Testing exhaust color".) black".
standard value. Perform following
4 Excessive blowby gas
• Blowby pressure is still high after KCCV checks.
filter element is replaced.
• Rotate KVGT shaft and check for play.
Defective KVGT seal on (Move KVGT vanes with hand in axial and Replace KVGT.
5
turbine side radial directions to make judgement.)
• Remove EGR valve and check stem seal,
guide, and stem.
6 Worn EGR valve guide Replace EGR valve.
• When EGR valve is remove, outlet port is
dirty with oil.
• Check oil level for excessive refilling.
7 Excessive refilling of oil (If oil level is excessive, oil will reach high Refill with oil to correct
temperatures and early deteriorates.) oil level.
• Visually check oil cooler element for
contamination. Clean or replace oil
8 Dirty oil cooler element
(Contaminated oil cooler element can cooler element.
increased oil temperature.)
standard value.
• Blowby pressure is still high after KCCV
filter element is replaced. Replace piston ring or
9 Broken or worn piston ring
• Measure compression pressure (see correct its installation.
• Check valve guide and stem seal.
• Remove cylinder head, and check inside
Worn or damaged valve Replace valve guide
10 guide or stem seal diameter of guide and stem seal for
damage. and stem seal.
(Reference: See "Maintenance standards".)
PC360LC-10 40-729
40 Troubleshooting
S-12 Fuel consumption is excessive (D65-B70-400-A-Z0-A)
Failure Fuel consumption is excessive.

information
Replace injector.
• Measure spill rate from injector.
Excessive spill of fuel from (Reference: See Testing and adjusting, Lots of dusts are is
1 injector "Measuring fuel delivery, return and probably in fuel. Check
leakage".) storage management
of fuel.
• Check fuel return piping for clogging.
Clean or replace fuel
2 Clogged fuel return piping (Injection rate may be increased due to
return piping.
clogged fuel return piping.)
does not change.
Fuel leakage from cylinder • Check for increased oil level. Repair defective parts.
4
head • Check for smell of diesel fuel.
• Check for increased engine oil level and
Fuel leakage from feed pump smell of diesel fuel. Replace feed pump oil
5
oil seal • Check feed pump oil seal. seal.
6 Fuel leakage outside engine • Check for fuel leakage outside engine. Repair defective parts.
40-730 PC360LC-10
40 Troubleshooting
S-13 Oil is in coolant (or coolant spurts or coolant level goes down) (PC400-
B40-400-A-Z0-A)
Failure Oil is in coolant (or coolant spurts or coolant level goes down)
Perform
troubleshooting for "S-
1 Milky engine oil • Engine oil level rises and oil is milky
16 Water mixes into
engine oil (milky)".
Damaged oil cooler element Replace oil cooler
2 • Check oil cooler element
element
• Coolant in radiator has excessive air
bubbles and blows back.
3 Damaged cylinder head • Overhaul engine and perform a pressure Replace cylinder head
tightness test on cylinder head to check for
abnormalities
• Coolant in radiator has excessive air
Damaged cylinder head bubbles and blows back. Replace cylinder head
4 gasket • Overhaul engine and check cylinder head gasket
gasket for abnormalities
• Engine oil level rises and oil is milky
Cracks or pitting in cylinder • Disassemble engine and check for cracks Replace cylinder block
5
block or pitting in cylinder block
PC360LC-10 40-731
40 Troubleshooting
S-14 Oil pressure drops (PC400-10D-400-A-Z0-A)
Failure Oil pressure drops

Related information • Confirm if machine has been operated on a slope steeper than specified in the
Operation and Maintenance Manual.
• Oil level in oil pan is low
1 Lack of oil in oil pan • Oil pressure monitor indicates low oil Add oil
pressure when operating on slopes
Defective oil pressure sensor, Replace oil pressure
• Check oil pressure sensor, wiring harness,
2 wiring harness sensor, wiring harness,
and connector
or connector
If oil is contaminated
with fuel, carry out
• Perform oil analysis and check for fuel in oil
3 Fuel in oil troubleshooting for "S-
• Engine oil smells of diesel fuel
15 Fuel mixes into
engine oil"
If oil is contaminated
• Perform oil analysis and check for water in with water, carry out
4 Water in oil oil troubleshooting for "S-
• Oil is milky 16 Water mixes into
engine oil (milky)"
• Check oil filter
(Reference: Oil filter has been used beyond
5 Clogged oil filter the specified period, oil heavily Replace oil filter
deteriorated, etc.)
• Water in oil can cause oil filter blockage
6 Clogged oil strainer • Check oil strainer Clean oil strainer
Crushed or clogged hydraulic Replace hydraulic
7 • Hydraulic piping is crushed or clogged
piping piping
• Check oil pump
8 Defective oil pump (worn or damaged gear) Replace oil pump
• Oil pump rotation is heavy or it has play
Defective regulator valve • Check valve spring for fatigue or damage Replace regulator
9
valve
• Valve and spring of oil pump relief valve is Replace oil pump relief
10 Defective oil pump relief valve fatigued, damaged. valve
Cracks in oil pump suction • Check around oil pump suction piping Replace oil pump
11 piping (cracked piping) suction piping
Defective seal between oil
12 pump and oil pump suction • Check seal Replace seal
piping
Replace boost oil
13 Defective boost oil pump • Check boost oil pump
pump
Defective boost oil pump relief • Check boost oil pump relief valve for fatigue Replace boost oil
14 or damage on valve and spring pump relief valve
valve
Oil leakage from EGR Replace EGR
15 hydraulic piping • Check EGR hydraulic piping
hydraulic piping
• Check main journal bearing
Replace main journal
16 Worn main journal bearing • Metallic powders are found in oil drained
bearing
from oil pan
• Check pin journal bearing
Replace pin journal
17 Worn pin journal bearing • Metallic powders are found in oil drained
bearing
from oil pan
Worn idler bushing, damaged Replace idler bushing
18 idler gear • Check idler bushing and idler gear
or idler gear
Breakage or falling off of Replace piston cooling
19 piston cooling nozzle • Check piston cooling nozzle
nozzle
40-732 PC360LC-10
40 Troubleshooting
S-15 Fuel mixes into engine oil (PC400-B31-400-A-Z0-A)
Failure Fuel mixes into engine oil (smells of diluted diesel fuel)
1 Defective injector • When a certain cylinder is cut out, engine Replace Injector
speed does not change
"Handling of cylinder cut-out operation".)
Fuel leakage from injector or
2 • Check injector or O-ring Replace injector O-ring
O-ring (spill circuit)
Defective seal between
• Check seal between injector and injection
3 injector and injection piping, Repair or replace
piping, and check injection piping for cracks
cracks in injection piping
• Confirm that fuel no longer mixes into oil
4 Defects in supply pump Replace supply pump
after supply pump is replaced
PC360LC-10 40-733
40 Troubleshooting
S-16 Water mixes into engine oil (milky) (D65-B32-400-A-Z0-A)
Failure Water mixes into engine oil (milky).

• If oil mixes into coolant, perform troubleshooting for "S-13 Oil mixes into coolant".
• If any failure code is displayed, perform troubleshooting for that code first.
When engine starting and stopping is frequently repeated in low ambient temperatures,
Related since KCCV is installed, condensed water vapor in blowby gas may mix into oil leading to
information milky oil or emulsified oil inside engine, but this is normal. This is not problem if coolant is
not leaking.
If coolant leakage is suspected from rapid drop of coolant level, perform following
troubleshooting procedures.
• Coolant containing COOLANT flows out
when gas piping are removed from EGR
cooler outlet.
(Check whether water contains COOLANT
or not. It can be condensed water.)
1 Cracks in EGR cooler (Reference: Note that cracks in EGR cooler Replace EGR cooler.
are caused by and preceded by drop of
coolant level of cooling system in some
cases. When replacing EGR cooler, check
cooling system piping and radiator for water
leakage.)
Damaged oil cooler element • Check oil cooler element and gasket Replace oil cooler
2 or gasket • Pressure test on oil cooler shows that water element or gasket.
leaks.
Replace cylinder head
Damaged cylinder head or • Disassemble engine to check cylinder head
3 or cylinder head
cylinder head gasket and cylinder head gasket.
gasket.
• Engine oil level increases and oil is milky.
Cracks or pitting in cylinder • Disassemble engine and check inside of Replace cylinder block.
4
block cylinder block for cracks or pitting.
40-734 PC360LC-10
40 Troubleshooting
S-17 Coolant temperature rises too high (overheating) (PC300-AL0-400-A-Z0-A)
Failure Coolant temperature rises too high (overheating).

information
• Check radiator core for clogging, and check
1 Clogged radiator core Clean radiator core.
fin for crush.
• Thermostat does not open at cracking
temperature.
2 Malfunction of thermostat Replace thermostat.
a Thermostat cracking temperature: 81 ± 2 °C
(Full open temperature: 94 °C)
• Error related to coolant temperature is Replace coolant
Defective coolant temperature temperature sensor,
3 gauge displayed, but measured value of radiator
coolant temperature is normal. monitor or wiring
harness.
Perform
troubleshooting for "S-
4 Increased fuel injection rate • Fuel injection rate is high.
12 Fuel consumption is
excessive".
5 Low coolant level • Check coolant level. for lowering. Refill with coolant.
Replace coolant
6 Leakage of coolant • Check water leakage from coolant piping.
piping.
• Visually check water pump.
(Check shaft seal for water leakage,
7 Breakage of water pump impeller for damage, and shaft for
Replace water pump.
breakage.)
Overheating due to increased
EGR ratio (EGR amount Replace mass air flow
• Check mass air flow and temperature
8 against fresh air amount) and temperature
caused by defective mass air sensor.
sensor.
flow and temperature sensor
Overheating due to increased
EGR ratio (EGR amount
• Check air cleaner and rectifying wire net for Repair or replace air
9 against fresh air amount)
deformation. cleaner.
caused by air cleaner
deformation
Defective cylinder head or • Check radiator coolant for excessive Perform
10 cylinder head gasket bubbles and spurt back. troubleshooting for "S-
13 Oil is in coolant".
• Open exhaust color inspection hole that is
just upstream of KDPF, and check exhaust
gas.
"Testing exhaust color".) Replace piston ring or
11 Defective piston ring • Measure compression pressure (see piston.
• Check piston ring and piston ring groove.
PC360LC-10 40-735
40 Troubleshooting
S-18 Unusual noise is heard (PC400-BA1-400-A-Z0-A)
Failure Unusual noise is heard.

• Check whether noise source is in or outside engine before starting troubleshooting.
• Engine runs in low-temperature mode while it is not warmed up sufficiently. Accordingly,
engine sound becomes slightly larger. This does not indicate abnormality, however.
Related • When engine accelerates, it switches into acceleration mode and its sound becomes
information slightly large further for up to approximately 3 to 5 seconds. This does not indicate
abnormality, however.
• Exhaust gas leaks from piping between
cylinder head and exhaust manifold,
Exhaust gas leakage from between exhaust manifold and KVGT, or Repair or replace
1 piping between KVGT outlet and KDPF. defective parts.
• Exhaust gas leaks from EGR piping or air
intake piping.
Vibration of exhaust piping or • Visually check for vibration. Check and retighten
2 piping brackets.
exhaust bellows
• Check whether KVGT shaft rotates.
3 Seized or broken KVGT (Move KVGT vanes with hand in axial and Replace KVGT.
radial directions to make judgement.)
Clean or replace
4 Internal damage of KDPF • Check inside of KDPF.
KDPF.
does not change.
• Check valve clearance.
6 Incorrect valve clearance (Reference: See Testing and adjusting, Adjust valve clearance.
Seized pin bushing, front Repair or replace
7 bearing, or main bearing • Check for metal particles in oil pan.
damaged parts.
• If metal particles is found in oil pan or oil
filter, overhaul engine and check piston ring
and cylinder liner.
Worn piston ring or cylinder Replace piston ring or
8 • Measure compression pressure (see
liner cylinder liner.
• Overhaul engine and check valves and Replace valve or
9 Damaged valve or rocker arm rocker arm parts. rocker arm.
10 Damaged idler gear • Overhaul engine and check idler gear parts. Replace idler gear.
40-736 PC360LC-10
40 Troubleshooting
S-19 Vibration is excessive (D65-BC0-400-A-Z0-A)
Failure Vibration is excessive

• If unusual noise is made and vibration is excessive, perform troubleshooting for "S-
Related information 18 Unusual noise is heard", too.
Loose engine mounting bolts, • Visually check for loose engine mounting Retighten bolts or
1 bolts, cracks in cushions, and hardening replace cushions
defective cushions
Worn faucet joint portion of • Check for worn faucet joint portion of front
2 Replace front support
front support trunnion support trunnion
• Visually check viscous damper for Replace engine
3 Damaged engine damper
discoloration damper
Defective output shaft or • Check for damage in output shaft or Replace defective
4 damper chamber damper chamber parts
Misalignment and facial runout
• Measure misalignment and facial runout at
at connection between engine Replace defective
5 connection between engine and hydraulic
and hydraulic pump are out of parts
pump
standard range.
6 Defective injector • When a certain cylinder is cut out, engine Replace injector
speed does not change
"Handling of cylinder cut-out operation".)
Worn main bearing, • If metal particles are found in oil pan or oil Correct or replace
7 connecting rod bearing filter, overhaul engine damaged parts
• If metal particles are found in oil pan or oil Correct or replace
8 Sticking valve or rocker arm filter, open head cover and check valves damaged parts
and rocker arms
• If metal particles are found in oil pan or oil
Replace camshaft
9 Worn camshaft bushing filter, overhaul engine and check camshaft
bushings
bushings
PC360LC-10 40-737
40 Troubleshooting
S-20 Air cannot be bled from fuel circuit (D65-A29-400-A-Z0-A)
Failure Air cannot be bled from fuel circuit

Related • If any error code is displayed, carry out troubleshooting for it first.
information
• When fuel feed pump switch is turned ON,
1 Insufficient fuel in tank pump operating sound is heard. Add fuel
• Even when fuel feed pump switch is turned
2 Low battery charge level Charge battery
ON, pump operating sound is not heard.
• Check drain valve of fuel prefilter for
Loose drain valve of fuel
3 loosening Close drain valve
prefilter
(Air leaking in due to loose drain valve)
4
• Air is discharged when the air is bled from
the fuel system Correct or replace fuel
(Reference: See Testing and adjusting, piping
"Bleeding air from fuel system")
"Checking fuel system for leakage")
• With fuel feed pump switch ON, voltage to
Replace fuel feed
7 Malfunction of fuel feed pump fuel feed pump is generated but pump does
pump
not operate.
Defective wiring harness of Replace wiring
8 • Check wiring harness
fuel feed pump harness
40-738 PC360LC-10
40 Troubleshooting
S-21 Frequent active regeneration (D65-AQ0-400-A-Z0-A)
Failure Frequent active regeneration

information
Frequently used for light load Perform Regeneration
• Soot accumulates when exhaust
1 operations such as simple for Service to burn
temperature does not increase.
traveling. away soot completely
• Open the exhaust color inspection hole in
front of KDPF, check the exhaust gas (refer Carry out
Exhaust gas color is bad standard value table) troubleshooting for "S-
2
(Reference: See Testing and adjusting, 9 Exhaust smoke is
"Measuring exhaust gas color".) black"
• If regeneration frequency does not return to
Bad exhaust color causing
3 normal after remedies for cause 2 are taken, Clean KDOC
KDOC face plugging
KDOC is plugged
Use proper oil
Improper oil used • Oil other than specified one is used specified in Operation
4
and Maintenance
Manual.
• If regeneration frequency does not return to
KCSF plugged due to
5 normal after remedies for cause 4 are taken, Clean or replace KCSF
improper oil used
KCSF is plugged
Carry out
Coolant leaking into exhaust troubleshooting for "S-
6 system • Check for low coolant level 16 Water mixes into
engine oil (milky)"
KCSF plugged due to coolant
7 • Check for plugging at KCSF inlet Clean or replace KCSF
leaking into exhaust system
Use proper fuel
8
and Maintenance
Manual
• KDOC deteriorated by high sulfur content
KDOC deterioration due to (If regeneration frequency does not return to
9 Replace KDOC
improper fuel used normal after remedies for causes 1 to 8 are
taken, KDOC is deteriorated)
• If regeneration frequency is not improved
10 Plugged KDOC after remedies on causes 1 to 9, KDOC is Clean KDOC
blocked.
11 Damaged KDOC • Check KDOC for damage Replace KDOC
PC360LC-10 40-739
40 Troubleshooting
S-22 Active regeneration takes time (D65-AQ1-400-A-Z0-A)
Failure Active regeneration takes time.
Related • Since the time required for manual stationary regeneration depends on the accumulated
information soot level, see failure code CA2639.

• KVGT may have mechanical failure. Check
it.
• If values of KDOC inlet temperature:
approximately 250°C or below and KVGT Replace the whole
solenoid current: approximately 1000 mA KVGT (including
1 Malfunction of KVGT remain unchanged after performing hydraulic actuator and
regeneration for service, KVGT is defective. KVGT position sensor).
• Since the time required for manual
stationary regeneration depends on the
accumulated soot level, see failure code
CA2639.
• Open exhaust color inspection hole being
just upstream of KDPF, and check exhaust Perform
Defective exhaust gas color gas (see Standard value table). troubleshooting for "S-
2
(Reference: See Testing and adjusting, 9 Exhaust smoke is
"Testing exhaust color".) black".
Plugged KDOC resulting from • If regeneration time is not improved after
3 remedies on cause 2, KDOC is plugged. Clean KDOC.
bad exhaust color
Perform
4 system • Check for low coolant level. 16 Water mixes into
Plugged KCSF due to coolant
5 • Check KCSF for plugging. Clean KCSF.
leaking into exhaust system
Use proper fuel
6
and Maintenance
Manual.
• KDOC is deteriorated by high sulfur content.
Deteriorated KDOC due to (If regeneration time is not improved after
7 Replace KDOC.
use of improper fuel remedies on causes 1 to 6 are taken, KDOC
is deteriorated.)
• If regeneration time is not improved after
8 Plugged KDOC remedies on causes 1 to 7 are taken, KDOC Clean KDOC.
is blocked.
9 Damaged KDOC • Check KDOC for damage. Replace KDOC.
40-740 PC360LC-10
40 Troubleshooting
S-23 White smoke is exhausted during active regeneration (PC400-AQ2-400-A-Z0-A)
Failure White smoke is exhausted during active regeneration.

• White smoke may be observed for a short time immediately after engine is started in cold
Related weather or during regeneration, but this is normal.
information • If any failure code is displayed, perform troubleshooting for that code first.
Perform
1 system • Check for low coolant level. 16 Water mixes into
Plugged KDOC due to • If white smoke problem is not resolved after
coolant leaking into exhaust remedies for cause 1 are taken, KDOC is Clean or replace
2
system plugged. KDOC.
Use proper fuel
3
and Maintenance
Manual.
• KDOC is deteriorated by high sulfur content.
Deteriorated KDOC due to (If white smoke problem is not resolved after
4 Replace KDOC.
use of improper fuel remedies for causes 1 to 3 are taken, KDOC
is deteriorated.)
• If white smoke problem is not resolved after
5 Plugged KDOC remedies for causes 1 to 4 are taken, KDOC Clean KDOC.
is plugged.
6 Damaged KDOC • Check KDOC for damage. Replace KDOC.
7 Damaged KCSF • Check KCSF for damage. Replace KCSF.
PC360LC-10 40-741
40 Troubleshooting
40-742 PC360LC-10
SHOP MANUAL
HYDRAULIC EXCAVATOR
PC360LC-10
Model Serial Number
PC360LC-10 70001 and up
50 Disassembly and assembly

7 50 Disassembly and assembly
PC360LC-10 50-1
Table of contents

50 Disassembly and assembly ........................................................................................................... 50-1
Related information on disassembly and assembly ........................................................................ 50-4
How to read this manual ....................................................................................................... 50-4
Coating materials list ............................................................................................................ 50-6
Special tools list ................................................................................................................. 50-10
Sketches of special tools .................................................................................................... 50-15
Engine and cooling system ........................................................................................................ 50-18
Removal and installation of supply pump assembly............................................................... 50-18
Removal and installation of injector assembly....................................................................... 50-28
Removal and installation of cylinder head assembly.............................................................. 50-44
Removal and installation of radiator assembly ...................................................................... 50-66
Removal and installation of hydraulic oil cooler assembly ...................................................... 50-69
Removal and installation of aftercooler assembly .................................................................. 50-72
Removal and installation of engine and main pump assembly ................................................ 50-73
Removal and installation of engine front seal ........................................................................ 50-85
Removal and installation of engine rear seal......................................................................... 50-90
Removal and installation of fuel tank assembly ..................................................................... 50-97
Removal and installation of engine hood assembly ............................................................... 50-99
Removal and installation of KDPF assembly....................................................................... 50-102
Disassembly and assembly of KDPF ................................................................................. 50-109
Removal and installation of KCCV assembly ...................................................................... 50-118
Removal and installation of air cleaner assembly ................................................................ 50-120
Removal and installation of air conditioner compressor assembly......................................... 50-122
Removal and installation of air conditioner condenser assembly .......................................... 50-124
Power train system ................................................................................................................. 50-126
Removal and installation of travel motor and final drive assembly ......................................... 50-126
Disassembly and assembly of final drive ............................................................................ 50-127
Removal and installation of swing motor and swing machinery assembly .............................. 50-136
Disassembly and assembly of swing machinery.................................................................. 50-138
Removal and installation of swing circle assembly .............................................................. 50-145
Undercarriage and frame......................................................................................................... 50-146
Separation and connection of track shoe assembly ............................................................. 50-146
Removal and installation of sprocket.................................................................................. 50-149
Removal and installation of idler and idler cushion assembly ............................................... 50-150
Disassembly and assembly of idler .................................................................................... 50-151
Disassembly and assembly of idler cushion........................................................................ 50-154
Disassembly and assembly of track roller ........................................................................... 50-156
Disassembly and assembly of carrier roller......................................................................... 50-158
Removal and installation of revolving frame assembly ......................................................... 50-161
Removal and installation of counterweight assembly ........................................................... 50-163
Hydraulic system .................................................................................................................... 50-167
Removal and installation of center swivel joint assembly ..................................................... 50-167
Disassembly and assembly of center swivel joint ................................................................ 50-169
Removal and installation of hydraulic tank assembly ........................................................... 50-170
Removal and installation of main pump assembly ............................................................... 50-173
Removal and installation of control valve assembly ............................................................. 50-177
Disassembly and assembly of control valve........................................................................ 50-183
Disassembly and assembly of work equipment PPC valve................................................... 50-188
Disassembly and assembly of travel PPC valve.................................................................. 50-190
Work equipment ..................................................................................................................... 50-192
Removal and installation of bucket assembly...................................................................... 50-192
Removal and installation of arm assembly.......................................................................... 50-193
Removal and installation of work equipment assembly ........................................................ 50-195
Disassembly and assembly of work equipment cylinder....................................................... 50-198
Removal and installation of operator's cab assembly........................................................... 50-204
50-2 PC360LC-10
Table of contents
Removal and installation of operator cab glass (adhered glass) ........................................... 50-209
Removal and installation of front window assembly ............................................................. 50-219
Removal and installation of floor frame assembly................................................................ 50-225
Removal and installation of air conditioner unit assembly..................................................... 50-231
Removal and installation of operator's seat......................................................................... 50-235
Removal and installation of seat belt .................................................................................. 50-237
Removal and installation of front wiper assembly ................................................................ 50-239
Removal and installation of engine controller assembly ....................................................... 50-246
Removal and installation of pump controller assembly......................................................... 50-249
Removal and installation of machine monitor assembly ....................................................... 50-252
Removal and installation of pump swash plate sensor ......................................................... 50-254
Removal and installation of mass air flow and temperature sensor ....................................... 50-255
Removal and installation of KOMTRAX terminal assembly .................................................. 50-256
PC360LC-10 50-3
Related information on disassembly and assembly
Related information on disassembly and assembly (ALL-3851-001-A-00-A)
How to read this manual (ALL-0320-011-A-00-A)

(Rev.2010.10)
Removal and installation of TTTT assembly • Common tools that are necessary for installation
Special tools are described as [1], [2] ... etc. and their part
• Special tools which are necessary for removal or numbers, part names and quantities are not
installation of assemblies are described as described.
A1•••X1 etc. and their part numbers, part names, • Marks shown in the installation section are
necessities, and quantities are described in the explained below.
special tool list. k: This mark indicates safety-related
• Marks used in the column of necessity are precautions which must be followed when
explained below. performing the work.
t: Tools are not substituted, must always be
equipped (used). a : This marks gives guidance or precautions
q: Tools extremely useful if available or tools when performing the work.
that can be substituted with commercially
available tool. 4 : This mark shows the weight of a part or
• For details and the sketches of the special tools, the assembled parts for a device.
see "special tool list" and "sketches of special
tools". 2 : This mark indicates a specific coating
Removal agent to be used.
• In the removal section, the work procedures, 3 : This mark indicates the specified
precautions and know-how to do the work and tightening torque.
the amount of oil and coolant to be drained are
described. 5 : This mark indicates the amount of oil or
• Common tools that are necessary for the coolant to be added.
removal work are indicated as [1], [2] ... etc. and
their part numbers, part names and quantities Disassembly and assembly of TTTT assembly
are not described. Special tools
• Marks used in the removal section are explained • Special tools which are necessary for
below. disassembly and assembly of assemblies are
described as A1•••X1 etc. and their part
k: This mark indicates safety-related numbers, part names, necessities, and
precautions which must be followed when quantities are described in the special tool list.
performing the work. • Marks used in the column of necessity are
explained below.
a : This mark gives guidance or precautions when t: Tools are not substituted, must always be
performing the work. equipped (used).
[*1]: This mark indicates that instructions or q: Tools extremely useful if available or tools
precautions for the assembly installation work are that can be substituted with commercially
given in the installation section. available tool.
• For details and the sketches of the special tools,
6 : This mark shows the amount of oil or see "special tool list" and "sketches of special
coolant to be drained. tools".
Disassembly
4 : This mark shows the weight of a part or • In the disassembly section, the work
the assembled parts for a device. procedures, precautions and know-how to do
Installation the work, and the amount of oil and coolant to be
• Unless otherwise instructed the installation of drained are described.
assemblies is to be made in the reverse order to • Common tools that are necessary for the
removal. disassembly work are indicated as [1], [2] ... etc.
• Instructions and precautions for assembly and their part numbers, part names, and
installation are shown with [*1] mark in the quantities are not described.
removal section, identifying which step the • Marks used in the disassembly section are
instructions are intended for. explained below.
50-4 PC360LC-10
k: This mark indicates safety-related

precautions which must be followed when
performing the work.
a : This marks gives guidance or precautions

when performing the work.
6 : This mark shows the amount of oil or

coolant to be drained.
4 : This mark shows the weight of a part or

the assembled parts for a device.
Assembly
• In the assembly section, the work procedures,
precautions and the know-how to do the work,
and the amount of oil or coolant to be added are
described.
• Common tools that are necessary for the
disassembly work are indicated as [1],[2] ... etc.
and their part numbers, part names, and
quantities are not described.
• Marks used in the assembly section are
explained below.
k: This mark indicates safety-related
precautions which must be followed when
a : This mark gives guidance or precautions when

4 : This mark shows the weight of a part or

the assembled parts for a device.
2 : This mark indicates a specific coating
agent to be used.
3 : This mark indicates the specified
tightening torque.
5 : This mark indicates the amount of oil or

coolant to be added.
PC360LC-10 50-5
Coating materials list (ALL-3540-071-A-00-A)

(Rev.2012.11)
a The recommended coating materials such as adhesives, gasket sealants, and greases used for
disassembly and assembly are listed below.
a For coating materials not listed below, use the equivalent of products shown in this manual.
Adhesive
Komatsu code Part No. Capacity Container Main features and applications
• Use to prevent rubber gaskets, rubber
LT-1A 790-129-9030 150 g Tube cushions, and cork plugs from coming
out.
• Use for plastic (except polyethylene,
20g polypropylene, tetrafluoroethylene, and
Polyethylene vinyl chloride), rubber, metal, and non-
LT-1B 790-129-9050 (2 pcs. container metal parts which require immediate
contained)
and strong adhesion.
• Features: Resistance to heat and
50 g Polyethylene chemicals
LT-2 790-129-9180
container • Use to fix and seal bolts and plugs.
Adhesive:
790-129-9060 1 kg • Use to bond and seal metal, glass and
LT-3 (Set of adhesive Can
Hardener: plastics.
and hardener)
500 g
250 g Polyethylene • Use to seal plugs for blank holes.
LT-4 790-129-9040
container
• Heat-resistant seal used to repair
Holtz MH705 790-129-9120 75 g Tube engines
• Instantaneous adhesive
50 g Polyethylene • Curing time: From 5 sec. to 3 min.
ThreeBond 1735 790-129-9140 • Use mainly to bond metals, rubbers,
container
plastics, and woods.
• Instantaneous adhesive
2g • Quick-curing type (max. strength is
Aron Alpha 201 Polyethylene
790-129-9130 (5 pcs. obtained after 30 minutes)
container
contained) • Use mainly to bond rubbers, plastics,
and metals.
• General-purpose instantaneous
adhesive with excellent resistance to
Loctite 499 428-99-80070 20 g Tube heat and impact
• Use on the bushing mounting faces of
axle supports.
• Features: Resistance to heat and
Polyethylene chemicals
Loctite 648-50 79A-129-9110 50 cc • Use for fitted portions used at high
container
temperatures.
50-6 PC360LC-10
Liquid gasket
• Use to seal various thread portions,
LG-5 Polyethylene pipe joints, and flanges.
790-129-9080 1 kg
ThreeBond 1110F container • Use to seal taper plugs, elbows, and
nipples for hydraulic piping.
• Features: Silicon-based heat and
cold-resistant sealant
LG-6 • Use to seal thread portions and flange
790-129-9160 250 g Tube
ThreeBond 1215 surface.
• Use to seal oil pan, final drive case,
etc.
• Features: Silicon-based quick-curing
LG-7 sealant
ThreeBond 790-129-9170 150g Tube • Use to seal flywheel housing, intake
1207C manifold, oil pan, thermostat housing,
etc.
LG-8 • Features: Silicon-based, heat and
cold-resistant, vibration-resistant,
ThreeBond 419-15-18131 100 g Tube impact-resistant sealant
1207B • Use to seal transfer case, etc.
• Use for rough surfaces such as the
LG-9 circle gear top seal which is not
ThreeBond 790-129-9310 200 g Tube clamped by bolts, gaps in the weld
1206D which must be caulked, etc.
• Can be coated with paint.
LG-10 • Use as lubricant or sealant when the
ThreeBond 790-129-9320 200 g Tube radiator hoses are put on.
1206E • Can be coated with paint.
• Feature: Can be used together with
LG-11 solid gaskets.
790-129-9330 200 g Tube
ThreeBond 1121 • Use for covers of the transmission
case and steering case etc.
ThreeBond 1211 790-129-9090 100 g Tube • Liquid gasket used to repair engine
Molybdenum disulfide lubricant

• Use to prevent galling and seizure of
press-fitted portions, shrinkage-fitted
LM-P 09940-00040 200 g Tube portions, and thread portions.
• Use to lubricate linkages, bearings,
etc.
• Spray type
• Thin molybdenum disulfide films are
made on metal surfaces to prevent the
LM-S 09995-00250 190 g Can metals from galling.
• Use for the drive shaft splines, needle
bearings, pins and bolts of various
links, etc.
PC360LC-10 50-7
Seizure prevention compound

• Feature: Seizure and galling
prevention compound with metallic
LC-G super-fine-grain, etc.
— — Can
NEVER-SEEZ • Use for the mounting bolt in the high
temperature area of the exhaust
manifold and the turbocharger, etc.
Grease
SYG2-400LI-A
G2-LI • Lithium grease with extreme pressure
SYGA-16CNLI
G0-LI (*) Various Various lubrication performance, general
SYG0-400LI-A(*) purpose type
*: For cold regions
SYG0-16CNLI(*)
• Use for parts under heavy load.
Caution:
• Do not use this grease for rolling
Molybdenum SYG2-400M 400 g x 10 Bellows-type bearings like swing circle bearings,
disulfide grease SYG2-400M-A 400 g x 20 container etc. and splines.
LM-G (G2-M) SYGA-16CNM 16 kg Can • Use this grease for work
equipment pins only when
installing them, but do not use it
afterward.
Hyper White
SYG2-400T • Higher seizure resistant, heat
Grease Bellows-type
SYG2-16CNT 400 g resistant and water resistant than
G2-T container molybdenum disulfide grease.
SYG0-400T(*) 16 kg • Not conspicuous on machine since
G0-T (*) Can
SYG0-16CNT(*) color is white.
*: For cold regions
Bio grease
G2-B SYG2-400B
SYGA-16CNB 400 g Bellows-type • Since this grease is biodegradable in
G2-BT (*) container short period, it has less impact on
*: For use at high SYG2-400BT(*) 16 kg microorganisms, animals, and plants.
Can
temperature and SYGA-16CNBT(*)
under high load
• Silicone grease with wide usable
temperature range, high resistance to
G2-S thermal-oxidative degradation and
— 200 g Tube performance to prevent deterioration
ThreeBond 1855 of rubber and plastic parts
• Use for oil seals of the transmission,
etc.
• Urea (organic system) grease with
heat resistance and long life.
G2-U-S Enclosed type.
427-12-11871 2 kg Can • Use for rubber, bearing and oil seal in
ENS grease damper.
Caution: Do not mix it with lithium
grease.
50-8 PC360LC-10
Primer
Glass • Use to accelerate hardening of
Loctite 712 428-99-80080 100 ml
container instantaneous adhesive.
• Use as primer for painted cab
Sunstar Paint Glass sheet metal surface.
Primer 580 Super 20 ml (Effective period: 4 months after
container
manufacture)
417-926-3910
• Use as primer for cab glass
Sunstar Glass Glass surface.
20 ml
For adhering cab glass

Primer 580 Super container (Effective period: 4 months after
manufacture)
• Use as primer for painted cab
Sunstar Paint Glass sheet metal surface.
22M-54-27230 20 ml (Effective period: 4 months after
Primer 435-95 container
manufacture)
• Use as primer for black ceramic-
coated glass surface and for hard
Sunstar Glass polycarbonate-coated surface.
22M-54-27240 150 ml Steel can
Primer 435-41 (Effective period: 4 months after
manufacture)
• Use as primer for sash (Almite)
Sunstar Sash Glass (Effective period: 4 months after
22M-54-27250 20 ml
Primer GP-402 container manufacture)
Adhesive
• Use "S" in high temperature

season and "W" in low
Sunstar Penguin
Polyethylene temperature season as adhesive

Seal 580 Super 417-926-3910 320 ml for glass.
container
"S" or "W" (Effective period: 4 months after
manufacture)
• Use as adhesive for glass.

Sika Japan, Cartridge (Effective period: 6 months after
20Y-54-39850 310 ml
Sikaflex 256HV manufacture)
Ecocart • Use as adhesive for glass.
Sunstar Penguin
22M-54-27210 320 ml (Special (Effective period: 6 months after
Super 560
container) manufacture)
Caulking material
• Use to seal joints of glass parts.
Sunstar Penguin
417-926-3920 330 ml Cartridge (Effective period: 4 months after

Seal No.2505 manufacture)
• Use to seal front window.
Sekisui Silicone Cartridge (Effective period: 6 months after
20Y-54-55130 333 ml
Sealant 83 manufacture)
• Use to seal glass-to-glass joint.
GE Toshiba Translucent white seal.
Silicones 22M-54-27220 333 ml Cartridge
(Effective period: 12 months after
TOSSEAL 381 manufacture)
PC360LC-10 50-9
Special tools list (PC300-3530-061-A-00-A)
a Tools with part number 79*T-***-**** are not supplied (to be locally manufactured).
a Necessity
t: Tools are not substituted, must always be equipped (used).
q: Tools extremely useful if available or tools that can be substituted with commercially available tool.
a New/redesign
N: Tools with new part numbers, newly developed for this model.
R: Tools, with advanced part numbers, developed by improving existing tools for other models.
Blank: Tools already available for other models that can be used without any modification
a Tools marked with Q in the sketch column have the sketches. (See Sketches of special tools)
New/redesign
Necessity
Sketch
Sym- Nature of work,
Q'ty
Work item Part No. Part name
bol remarks
t 1 Adjustment of valve
1 795-799-1131 Gear
clearance
Removal and Removal of supply
2 795-799-1390 Remover t 1
installation of supply pump assembly
pump assembly Removal and
Commercially installation of supply
3 Wobble extension bar q 1
available pump assembly
Removal and Removal of injector
installation of 4 795-799-6700 Puller t 1
assembly
injector assembly
and cylinder head Removal of inlet
5 795-799-8150 Remover q 1
assembly connector
Removal and Wrench (angle) Angle tightening of
6 790-331-1120 q 1
installation of bolt
cylinder head Check of cylinder
7 795-790-4510 Gauge q 1
assembly head bolt length
Removal and A Installation of engine
installation of engine 8 795-799-8120 Installer q 1
front seal
front seal
Removal and 9 790-501-2001 Repair stand t 1 Fixing of engine
installation of engine
rear seal 10 790T-901-6030 Adapter t 1 Q assembly
Removal and Removal and
installation of engine installation of engine
11 795-799-9300 Lifting tool q 1
and main pump and main pump
assembly assembly
Removal,
installation, Removal and
Commercially Long socket (7/16 in)
disassembly and 12 q 1 installation of V-clamp
available
assembly of injector and band
and KDPF
Disassembly and Removal and
Commercially Long socket (1/2 in)
assembly of KDPF 13 q 1 installation of V-clamp
available
50-10 PC360LC-10
New/redesign
Necessity
Sketch
Q'ty
bol remarks
1 796T-626-1110 Push tool q 1 Q Press fit of bearing

3 790-201-2480 Push tool t 1 Press fit of bearing
Disassembly and 790-101-5401 Push tool kit q 1
assembly of swing
motor and swing E 790-101-5521 • Plate 1
4 Press fit of oil seal
machinery 790-101-5421 • Grip 1
01010-51240 • Bolt 1
5 793T-815-1110 Push tool t 1 Q Press fit of bearing
796-627-1610 Wrench assembly t 1
796-627-1620 • Wrench 1 Removal and
1 installation of ring nut
796-427-1140 • Pin 3
01314-20612 • Screw 3
t 1 Installation of floating
2 796T-627-1710 Installer Q
seal
796T-627-1720 Push tool t 1 Q
Disassembly and 790-101-2510 Block t 1
assembly of final F
791-830-1320 Rod t 2
drive
01580-11613 Nut t 2 Installation of hub
3 assembly
790-101-2570 Plate t 2
01643-31645 Washer t 2
790-105-2100 Jack assembly t 1
790-101-1102 Pump t 1
Tightening of cover
4 790-331-1110 Wrench t 1
mounting bolt
Disassembly and Installation of floating
J 796-570-1020 Installer t 1
assembly of idler seal
Disassembly and
assembly of track K 796-670-1010 Installer
seal
roller
Disassembly and
assembly of carrier L 791-430-3230 Installer
seal
roller
791-685-8006 Compressor t 1
791-635-3160 Extension t 1 Disassembly and
1 Cylinder (686 kN {70 assembly of idler
Disassembly and 790-101-1600 t 1 cushion
ton})
assembly of idler M Pump
790-101-1102 t 1
cushion
790-201-1990 Plate t 1
2 790-101-5021 Grip t 1 Press fit of dust seal
01010-50816 Bolt t 1
1 791-630-3000 Remover and installer t 1
Separation and Removal and
Cylinder (980 kN {100
connection of track N 2 790-101-1300 t 1 installation of master
ton})
shoe assembly pin
3 790-101-1102 Hydraulic pump t 1
PC360LC-10 50-11
New/redesign
Necessity
Sketch
Q'ty
bol remarks
Removal and 1 796-460-1210 Oil stopper q 1

installation of
hydraulic oil cooler
To stop flow of oil from
assembly, engine R
2 796-770-1320 Adapter q 1 hydraulic tank
and main pump
assembly, and main
pump assembly
790-101-2501 Push-puller q 1
790-101-2510 • Block 1
790-101-2520 • Screw 1
Disassembly and 791-112-1180 • Nut 1
Removal of rotor and
assembly of center S 790-101-2540 • Washer 1 ring
swivel joint 790-101-2630 • Leg 2
790-101-2570 • Plate 4
790-101-2560 • Nut 2
790-101-2650 • Adapter 2
50-12 PC360LC-10
New/redesign
Necessity
Sketch
Q'ty
bol remarks
796-946-1310 Guide f 21.8 mm

t 1
(For 723-46-40100 and 723-46-40601)
796-946-1410 Guide f 21.6 mm
t 1
(For 723-46-47500)
796-946-1810 Guide f 21.2 mm
1 t 1
(For 723-46-43100 and 723-46-43400)
796-946-2110 Guide f 20.9 mm
t 1
(For 723-46-44100)
796-946-2210 Guide f 20.6 mm
t 1
(For 723-46-45100 and 723-46-45700)
796-946-1320 Guide f 21.8 mm
t 1
(For 723-46-40100 and 723-46-40601)
796-946-1420 Guide f 21.6 mm
t 1
(For 723-46-47500)
796-946-1520 Guide f 21.6 mm Replacement of
Disassembly and t 1
(For 723-46-42800) pressure
assembly of control T 2 compensation valve
valve 796-946-1820 Guide f 21.2 mm
t 1 seal
(For 723-46-43100 and 723-46-43400)
796-946-2120 Guide f 20.9 mm
t 1
(For 723-46-44100)
796-946-2220 Guide f 20.6 mm
t 1
(For 723-46-45100 and 723-46-45700)
796-946-1330 Sleeve
t 1
(For 723-46-40100 and 723-46-40601)
796-946-1430 Sleeve
t 1
(For 723-46-42800 and 723-46-47500)
796-946-1830 Sleeve
3 t 1
(For 723-46-43100 and 723-46-43400)
796-946-2130 Sleeve
t 1
(For 723-46-44100)
796-946-2230 Sleeve
t 1
(For 723-46-45100 and 723-46-45700)
PC360LC-10 50-13
New/redesign
Necessity
Sketch
Q'ty
bol remarks
790-502-1003 Cylinder repair stand q 1 Disassembly and

1 assembly of work
790-101-1102 Pump q 1 equipment cylinder
790 to 102 to Wrench assembly t 1 Removal and
4300 installation of piston
2
790 to 102 to t 1 ring
Pin
4310
790 to 720 to Expander
3 q 1
1000
796 to 720 to Installation of piston
Rubber band q 1 ring
1680
4
07281 to Clamp q 1
01589
790 to 201 to
Push tool kit t 1
Disassembly and 1702
assembly of work U • Push tool (for boom
790-201-1851 and bucket) 1
equipment cylinder
5 790-201-1861 • Push tool (for arm) 1 Press fit of bushing
790 to 101 to Grip 1
5021
01010 to
Bolt 2
50816
790 to 201 to
Push tool kit t 1
1500
• Plate (for boom and
790-201-1660 bucket) 1
6 790-201-1670 • Plate (For arm) 1 Press fit of dust seal
790 to 101 to • Grip 1
5021
01010 to
• Bolt 2
50816
796-670-1100 Remover t 1
796-670-1110 • Sleeve 1
796-670-1120 • Plate 1
796-670-1130 • Screw 1
Removal and
791-775-1150 • Adapter 1 Removal of boom foot
installation of work V
01643-33080 • Washer 1 pin
equipment assembly
01803-13034 • Nut 1
Puller (490 kN {50 ton}
790-101-4000 t 1
long)
790-101-1102 Pump (294 kN {30 ton}) t 1
Removal and 1 793-498-1210 Lifter (Suction cup) t 2 Holding of glass
installation of
operator's cab glass X
(adhered window 2 20Y-54-13180 Stopper rubber t 2 Fixing of glass
glass)
Removal and Commercially Impact wrench
1 q 1
installation of available
counterweight Z
Commercially Width across flats: 55
assembly 2 Socket wrench q 1
available mm
50-14 PC360LC-10
Sketches of special tools (PC300-3531-066-A-00-A)
Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.
A10: Adapter
E1: Push tool
PC360LC-10 50-15
E5: Push tool
F2: Installer
50-16 PC360LC-10
F3: Push tool
PC360LC-10 50-17
Removal and installation of supply pump assembly (PC300-AD70-924-K-00-A)
a Special tools 1) Loosen two mounting bolts (10).

a One more mounting bolt (10) is at the
Necessity
Symbol
bottom of air conditioner compressor
Q'ty
Part No. Part name
assembly (9).
2) Move air conditioner compressor assembly
1 795-799-1131 Gear t 1 (9) and bracket (11) together in the loosening
2 795-799-1390 Remover t 1 direction of belt (12).
A 3) Remove loosened air conditioner
Commercially Wobble extension
3 q 1 compressor belt (12). [*2]
available bar
4) Remove four mounting bolts (13), disconnect
k Turn the battery disconnect switch to the air conditioner compressor assembly (9)
OFF position and remove the key. from bracket (11), and move it to a place
where it is not an obstacle to the work. [*3]
Removal (PC300-AD70-520-K-00-A)
1. Close the fuel stop valve at the bottom of the fuel

tank.
3. Remove fan guard (1).
4. Disconnect air conditioner hose clamp (2).
5. Remove U-bolt (3) to remove air intake tube (4)
from the KVGT. [*1]
11.Remove KCCV ventilator assembly (14). For

details, see "Removal and installation of KCCV
assembly".
12.Remove frame (15).
6. Remove step (5).

7. Remove frames (6).
9. Disconnect solenoid clutch connector AC03 (8)
of the air conditioner compressor.
10.Remove air conditioner compressor (9)
50-18 PC360LC-10
13.Remove air cleaner top cover (16) according to 14.Remove cover (18).
the following procedure.
15.Open the side cover on the right side of the

1) Lift up air cleaner top cover (16) to machine, remove bolts (19), and disconnect
disconnect it from the air inlet of air cleaner receiver (20) and bracket together.
(17).
2) Lift up and remove air cleaner top cover (16)
slantways so that it does not interfere with
frame (A).
16.Remove U-bolt (21) fixing tube (23). [*4]

17.Remove hose (22). [*5]
3) After removing the air cleaner top cover,

cover the air inlet of air cleaner (17) with a
vinyl sheet etc.
a If dirt enters, it can cause engine failure.
PC360LC-10 50-19

20.Remove tube (23).
29.Disconnect fuel return hose (35) and fuel supply

hose (36).
21.Disconnect intake air heater E01 (26) and wiring
harness clamp (27). [*6]
22.Disconnect supply pump connector (28).
23.Remove brackets (29) and (30).
24.Remove bracket (11).
25.Remove base bracket (31).
30.Disconnect fuel hose (37) according to the

1) Loosen elbow (38) under fuel hose (37) and
direct it down.
2) While pressing locks (L) at the top and
bottom, disconnect fuel hose (37).
26.Remove cover (32).
31.Remove two fuel spray prevention caps (39).

27.Remove frame (33). 32.Remove sandwich clamp (40).
28.Remove cover (34). 33.Remove high-pressure tube (41).
34.Disconnect overflow tube (42).
50-20 PC360LC-10
35.Remove cap (43) of the front gear cover.

a Use a filter wrench etc. to remove cap (43).
39.Install tool A2 with bolts [1] (M8 x 1.25).

40.Tighten evenly bolts [1] of tool A2 to disconnect
the supply pump shaft from the supply pump
36.Remove nut (45) and washer (46) from supply gear.
pump shaft (44).
a After disconnecting, remove tool A2 and nut.
37.After removing the washer, tighten nut (45)

again lightly. 41.Remove bolts (49) and (50) to remove bracket
38.Rotate the crankshaft in the normal direction (51).
and bring stamp (a) of supply pump gear (47) to 42.Remove four mounting nuts (52) to remove
the top to set the No. 1 cylinder to the supply pump assembly (53).
compression top dead center (TDC). a Since nuts (52) on the cylinder block side are
a Use a mirror to check stamp (a) of the supply difficult to remove, use tool A3 (wobble
pump gear since the view is narrow. extension bar) to remove.
a When rotating the crankshaft in the normal

direction, remove cap (48) from the flywheel
housing and install tool A1, and then rotate
with the wrench.
PC360LC-10 50-21
Installation (PC300-AD70-720-K-00-A)
3. Install new O-ring (55) to the flange of the supply
pump assembly.
1. Rotate the crankshaft in the normal direction and
bring stamp (a) of the supply pump gear to the 2 O-ring (55):
top to set the No. 1 cylinder to the compression Engine oil (EO15W-40)
top dead center (TDC). 4. Install new O-ring (56) to the lubrication port of
the supply pump.
a Use a mirror to check stamp (a) of the supply
pump gear since the view is narrow. 2 O-ring (56):
a When rotating the crankshaft in the normal Engine oil (EO15W-40)
direction, remove cap (48) from the flywheel 5. Clean the outside contact face of the supply
housing and install tool A1, and then rotate pump shaft and the inside contact face of the
with the wrench. supply pump gear with contact cleaner.
6. Before installing the supply pump assembly,
check that the outside contact face of the supply
pump shaft and the inside contact face of the
supply pump gear are free from foreign material
and dry.
7. While matching dowel pin (54) of supply pump

shaft (44) with keyway (b) of supply pump gear
(47), push in supply pump assembly (53).
2. Before installing the supply pump, check that

dowel pin (54) of the supply pump shaft is not
damaged.
a If the dowel pin is damaged, replace the
supply pump and supply pump gear.
50-22 PC360LC-10
8. Fit washer (46) to supply pump shaft (44) and 14.Tighten nut (45).
tighten nut (45) lightly.
180 ± 13 Nm {18.4 ± 1.33 kgm}
9. Tighten nuts (52) lightly to a degree that they are

not loose to install supply pump assembly (53).
15.Install cap (43) of the front gear cover.
a Since nuts (52) on the cylinder block side are
difficult to install, use tool A3 (wobble
extension bar) to install.
a Take care that nuts (52) will not fall.
2 Mounting nut (52):
Adhesive (LT-2)
10.Tighten supply pump assembly mounting nuts
(52) to the specified torque.
43 ± 6 Nm {4.38 ± 0.61 kgm}
11.Tighten bolts (49) and (50) of bracket (51) lightly.
12.Tighten mounting bolt (50) on the cylinder head 16.Install fuel hose (37).
side.
a Clean the inside of the hose connector and
3 Mounting bolt (50) connect the connector securely.
43 ± 6 Nm {4.38 ± 0.61 kgm}
a Return elbow (38) to the horizontal position.
13.Tighten mounting bolt (49) on the supply pump
flange side.
77 ± 12 Nm {7.85 ± 1.22 kgm}
PC360LC-10 50-23
17.Install fuel return hose (35) and fuel supply hose

(36). 1) Loosen mounting bolts (98), (99), and (100)
of common rail (97), and then finger-tighten
3 Sleeve nut: them.
54 to 93 Nm {5.5 to 9.5 kgm}
2) Tighten high-pressure pipe (41) between the

18.Install the high-pressure pipe according to the supply pump and common rail to the
following procedure. specified torque.
k Do not bend the fuel high-pressure pipe Supply pump side: 19 mm
to collect before installing.
k Be sure to use the genuine high-pressure 3 Sleeve nut:
pipe fixing clamp and observe the 37 ± 4 Nm {3.77 ± 0.41 kgm}
tightening torque. 3) Tighten common rail mounting bolts (98),
(99) and (100) which were loosened.
k Install each high-pressure pipe and
harness at least 10 mm apart from each 3 Mounting bolt:
other. 43 ± 4 Nm {4.38 ± 0.41 kgm}
4) Loosen sandwich clamp (40) of high-
a A high-pressure pipe may cause fuel leakage pressure pipe.
if visible lengthwise slits (b) or dents (c) are 5) Tighten the bracket of sandwich clamp (40).
found at the joint's taper seal at part (a)
(within 2 mm from the end), or the stepped 3 Mounting bolt:
wear at part (d) (2 mm from the end of taper 24 ± 4 Nm {2.45 ± 0.41 kgm}
seal) is as severe as it can be felt with a 6) Tighten sandwich clamp (40).
fingernail. If there is any of these defects,
replace the high-pressure pipe. 3 Mounting bolt:
6 Nm {0.61 kgm}
7) Install two fuel spray prevention caps (39).
a Set the slits of each bellows out and
down.
50-24 PC360LC-10
a The fuel spray prevention caps are 2 Clamp bolt thread portion (BC):
installed so that fuel will not spout over Lubricant oil (ThreeBond PANDO 18B or
the hot part of the engine and catch fire equivalent)
when it leaks by any chance.
• If hoses are to be reused
8) Tighten overflow tube (42).
Install the clamp to the clamp mark put on the
3 Joint bolt: hose.
24 ± 4 Nm {2.45 ± 0.41 kgm} 3 Clamp bolt:
16 to 17 Nm {1.6 to 1.7 kgm}
• When using a new hose
Tighten the clamp so that dimension (BDG) is 4
to 7 mm.
• Carry out the rest of installation in the reverse

order to removal.
[*1]
3 Hose clamp:
10.5 ± 0.5 Nm {1.07 ± 0.05 kgm} [*6]
3 U-bolt mounting nut: 3 Intake air heater connector E01:
14.7 to 44.1 Nm {1.5 to 4.5 kgm} 4.0 ± 0.6 Nm {0.41 ± 0.15 kgm}
[*2] • Checking for fuel leakage (fuel system)
a Adjust the air conditioner compressor belt Check the fuel system for leakage. For details,
tension. For details, see Testing and adjusting, see Testing and adjusting, "Checking fuel
"Testing and adjusting air conditioner system for leakage".
compressor belt tension". • Bleeding air (fuel system)
Bleed air from the fuel system. For details, see
[*3]
3 Air conditioner compressor assembly system".
mounting bolt: Reference: High-pressure pipe and injection pipe
10.5 ± 0.5 Nm {1.07 ± 0.05 kgm} reinstallation procedure (when replacing a high-
pressure pipe or common rail).
[*4]
3 U-bolt mounting nut:
injection pipe to correct before installing.
10.8 to 26.5 Nm {1.1 to 2.7 kgm}
[*5] k Be sure to use the genuine clamp for the
high-pressure pipe and injection pipe, and
a Tighten the MIKALOR clamps at both ends of
observe the specified tightening torque.
the tube according to the following procedure.
a Use new MIKALOR clamps. k Install each high-pressure pipe and wiring
harness at least 10 mm apart from each
a Impact wrench is not allowed to use.
other.
a With bridge (BR) set under the clamp bolt,
tighten the bolt so that bridge (BR) laps over with
the band by dimension (b) indicated below.
• Dimension (b): Min. 5 mm
PC360LC-10 50-25
a A high-pressure pipe or injection pipe may cause

fuel leakage if visible lengthwise slits (b) or dents
(c) are found at the joint's taper seal at part (a)
(within 2 mm from the end), or the stepped wear
at part (d) (2 mm from the end of taper seal) is
as severe as it can be felt with a fingernail. If
there is any of these defects, replace the high-
pressure pipe or injection pipe.
4. Tighten high-pressure pipes (81) to (86)

between the inlet connector and common rail.
3 Sleeve nut:
37 ± 4 Nm {3.77 ± 0.41 kgm}
5. Tighten common rail mounting bolts (98), (99)
1. Check that inlet connector (91) is fastened by
and (100).
tightening retaining nut (90) to the specified
torque.(6 places) 3 Mounting bolt:
3 Retaining nut (90): 43 ± 4 Nm {4.38 ± 0.41 kgm}
50 ± 4 Nm {5 ± 0.4 kgm}
2. Set common rail (97) and mounting bolts (98),
(99) and (100), then finger-tighten the mounting
bolts.
6. Tighten the bracket of the sandwich clamp which

is fixing high-pressure pipe (87) and injection
pipes (81) to (86).
a Install bracket (105) of high-pressure pipe #2
3. Tighten high-pressure pipe (87) between the (82) on bracket (106) and tighten it with bolt
supply pump and common rail. (103).
a Width across flats of sleeve nut a Tighten bracket (49) of high-pressure pipe #3
Supply pump side: 19 mm (83) with bolt (107) after installing air intake
Common rail side: 22 mm manifold (55).
3 Sleeve nut: 3 Mounting bolts (101) to (104), (107):

37 ± 4 Nm {3.77 ± 0.41 kgm} 24 ± 4 Nm { 2.45 ± 0.41 kgm}
7. Tighten sandwich clamp (89).
3 Mounting bolt:
6 Nm {0.61 kgm}
8. Install 14 fuel spray prevention caps (88).
50-26 PC360LC-10
a When installing the fuel spray prevention

caps, direct their slits outward or downward.
a The fuel spray prevention caps are installed
so that fuel will not spout over the hot part of
the engine and catch fire when it leaks by
any chance.
PC360LC-10 50-27
Removal and installation of injector assembly (PC300-AE60-924-K-00-A)

Necessity
Symbol
Q'ty
Part No. Part name
assembly (9).
4 795-799-6700 Puller t 1 direction of belt (12).
A 5 795-799-8150 Remover q 1 3) Remove loosened air conditioner
Long socket compressor belt (12). [*2]
Commercially
12 q 1 4) Remove four mounting bolts (13), disconnect
available (7/16 in)
air conditioner compressor assembly (9)
k Turn the battery disconnect switch to the from bracket (11), and move it to a place
OFF position and remove the key. where it is not an obstacle to the work. [*3]
Removal (PC300-AE60-520-K-00-A)

tank.
from the KVGT. [*1]

assembly".
6. Remove step (5).

50-28 PC360LC-10
13.Remove air cleaner top cover (16) according to


machine, remove bolts (19), and disconnect
receiver (20) and bracket together.
1) Lift up air cleaner top cover (16) to
disconnect it from the air inlet of air cleaner
(17).
frame (A).


vinyl sheet etc.

PC360LC-10 50-29
21.Disconnect intake air heater E01 (26) and wiring 30.Disconnect tube (44) under EGR valve (43).
31.Disconnect tube (45).

32.Remove EGR valve (43).
24.Disconnect EGR orifice temperature sensor

connector (33) of EGR valve piping (32).
25.Disconnect wiring harness connectors (34), (35),
and (36).
• Connector (34): KVGT position sensor
• Connector (35): KVGT speed sensor
• Connector (36): connector box
26.Disconnect wiring harness bracket (37).
27.Disconnect hoses (38) and (39).
k When disconnecting the hoses, always

disconnect at the intake manifold side to
avoid splashing oil to high temperature 33.Disconnect ambient pressure sensor (46).
area which causes fire. 34.Disconnect wiring harness clamp (47) and
bracket (48).
• Hose (38): KVGT control pressure circuit 35.Remove sandwich clamp (49) of the injection
• Hose (39): KVGT actuator drive pressure pipe.
circuit 36.Disconnect two wiring harness connectors (50).
28.Remove four mounting bolts (40) to remove
EGR valve piping (32). a Disconnect the remaining one connector
29.Loosen hose clamp (41) of EGR valve piping after removing the blowby hose.
(32) and remove it from tube (42). 37.Disconnect common rail pressure sensor (51).
38.Disconnect charge (boost) pressure and
temperature sensor connector (52).
39.Disconnect engine wiring harness (53) and
move it to a place where it is not an obstacle to
the work.
40.Disconnect hose clamp (183) and wiring
harness clamp (182), and remove cover (54).
50-30 PC360LC-10
41.Remove air intake manifold (55).
45.Disconnect tube clamp (62).

46.Remove KCCV outlet tube (63).
a Remove the hoses at both ends of tube (63)
together.
47.Remove KCCV crank pressure sensor mounting
bracket (184), and remove KCCV inlet hose
(64).
48.Disconnect hose clamp (65).

49.Disconnect blowby hose (66).
50.Disconnect harness connector (50) and move
engine wiring harness (53) to a place where it is
not an obstacle to the work.
51.Remove head cover (67).
42.By using tool A12 (long socket), remove V-
clamps (56) and (57).
a Make matchmarks on the tube and V-clamps
before removing.
a Width across flats of V-clamp fastening nut:
7/16 in (11.1 mm)
43.Disconnect tube (58) from KDPF piping bracket
(59).
44.Remove U-bolt (56) to remove tube (58).
a Take care that spacer (61) will not fall.
52.Loosen and remove cap (68) of the front gear

cover.
PC360LC-10 50-31
Cable color Cylinder No.

p Yellow May be installed in
1, 3, 5
q Orange reverse
r Red May be installed in
2, 4, 6
s Brown reverse
55.Remove plate (72) from rocker housing (73).
56.Loosen lock nuts (77) and then loosen
adjustment screws (78) two to three turns each
so that the valve spring tension will not be
applied to rocker arm mounting bolts (75).
57.Remove mounting bolts (74) to remove rocker
housing (73).
53.Rotate the crankshaft in the normal direction
and bring stamp (a) of supply pump gear (69) to
the top to set the No. 1 cylinder to the
compression top dead center (TDC).
a Use a mirror to check stamp (a) of supply
pump gear (69) since the view is narrow.
with the wrench.
58.Remove 12 mounting bolts (75) to remove

59.Remove 12 push rods (79).
60.Remove crossheads (80).
54.Loosen the capture nut at the injector head and

disconnect injector wiring harness (71).
a Loosen the capture nuts alternately.
a The capture nut cannot be removed from the
wiring harness.
a Installed positions of harnesses
50-32 PC360LC-10
a Record the installed positions and directions

of the crossheads (shapes of holes at
portions (a) and (b)). (Reinstall them in the
same directions)
61.Remove 14 fuel spray prevention caps (88) of

high-pressure pipe (87) and injection pipes (81)
to (86).
62.Remove sandwich clamp (89) of high-pressure
pipe (87) and injection pipes (81) to (86).
a Take care that sandwich clamps will not fall.
63.Remove high-pressure pipe (87) and injection
pipes (81) to (86).
64.Remove retaining nut (90) and remove inlet

Installation (PC300-AE60-720-K-00-A)
connector (91).
a Check that the injector mounting bore is free
a Before removing retaining nut (90), remove from flaw, dirt, etc.
all soil, sand, etc. sticking around it.
a When replacing the injector with a new one, be
a Use tool A5 to remove inlet connector (91). sure to replace the inlet connector with a new
65.Remove holder mounting bolt (92). one, as well.
66.By using tool A4, remove holder (93) and
injector assembly (94) together. 1. Check inlet connector (91) visually. If it has any
of the following faults, replace it.
a Take care that dirt and foreign material will 1) There is a burr or a worn part at front end (a)
not enter the injector mounting bore. or rear end (b) of the inlet connector.
a Never grip the solenoid valve on the top of 2) There is foreign material in the edge filter at
the injector with pliers etc. rear end (c) of the inlet connector.
3) Cracks or deterioration is recognizable in O-
ring of the inlet connector upper (d) portion.
4) There is a worn part or an uneven seat
contact mark on seat face (e) at the front end
of the inlet connector.
PC360LC-10 50-33
a If high-pressure fuel leaks through the

inlet connector, the seat face has fine
streaks or flaws. If any of these
phenomena is detected, replace the inlet
connector and injector.
6. Tighten inlet connector (91) lightly with retaining

nut (90).
2 O-ring of inlet connector (91) and
mounting hole on cylinder head side:
a After tightening lightly as above, tighten to
the specified torque. Be sure to tighten each
bolt and nut to the respective specified
torques. If a bolt or a nut is tightened
insufficiently or too strongly, fuel may leak
into the engine.
3 Retaining nut (90) (tightening lightly):
15 ± 5.0 Nm {1.53 ± 0.51 kgm}
2. Fit gasket (95) and O-ring (96) to fuel injector

(94).
2 O-ring (96) of injector (94) and injector
mounting hole:
3. Install holder (93) to injector (94).
a Match concave (A) and convex (B) portions
with each other.
7. Tighten mounting bolts (92) of holder (93)
alternately.
10 ± 2 Nm {1.02 ± 0.2 kgm}
a The top of holder (93) must be in parallel with
the top of the cylinder head.
• Allowable angle: 2.4 °
8. Tighten inlet connector (91) with retaining nut
2 Retaining nut (90) and "f" (hatched
portion) in figure of cylinder head:
4. Insert injector (94) into the cylinder head with the GE TOSHIBA SILICONES
fuel inlet toward the air intake manifold. TOSSEAL381
5. Finger-tighten mounting bolts (92) of holder (93)
three to four turns.
50-34 PC360LC-10

50 ± 4 Nm {5 ± 0.4 kgm}
1) Check that inlet connector (91) is fastened by

torque.(6 places)
50 ± 4 Nm {5 ± 0.4 kgm}
2) Loosen mounting bolts (98), (99), and (100)
of common rail (97), and then finger-tighten
them.
9. Install the high-pressure pipe and injection pipe


3) Tighten high-pressure pipe (87) between the
k Be sure to use the genuine clamp for the supply pump and common rail.
high-pressure pipe and injection pipe,
and observe the specified tightening
torque. Supply pump side: 19 mm
k Install each high-pressure pipe or
3 Sleeve nut:
injection pipe and wiring harness at least
10 mm apart from each other. 37 ± 4 Nm {3.77 ± 0.41 kgm}
a A high-pressure pipe or injection pipe may

cause fuel leakage if visible lengthwise slits
(b) or dents (c) are found at the joint's taper
seal at part (a) (within 2 mm from the end), or
the stepped wear at part (d) (2 mm from the
end of taper seal) is as severe as it can be
felt with a fingernail. If there is any of these
defects, replace the high-pressure pipe or
injection pipe.
PC360LC-10 50-35
4) Tighten high-pressure pipes (81) to (86)

between the inlet connector and common
rail.
3 Sleeve nut:
37 ± 4 Nm {3.77 ± 0.41 kgm}
5) Tighten common rail mounting bolts (98),
(99) and (100).
3 Mounting bolt:
43 ± 4 Nm {4.38 ± 0.41 kgm}
6) Tighten the bracket of the sandwich clamp

which is fixing high-pressure pipe (87) and
injection pipes (81) to (86).
a Install bracket (105) of high-pressure pipe
#2 (82) on bracket (106) and tighten it
with bolt (103).
a Tighten bracket (49) of high-pressure
pipe #3 (83) with bolt (107) after installing
air intake manifold (55).
3 Mounting bolts (101) to (104), 10.Install push rod (79).
(107): Check that push rod (79) is in the tappet.
24 ± 4 Nm {2.45 ± 0.41 kgm} 2 Push rod socket:
7) Tighten sandwich clamp (89).
3 Mounting bolt: 11.Install crosshead (80).
6 Nm {0.61 kgm} a When reusing the crosshead, install the
8) Install 14 fuel spray prevention caps (88). same intake and exhaust valves in the same
a Set the slits of each bellows out and direction because the shapes of its holes (a)
down. and (b) are different. (A new crosshead may
be installed in either direction.)
a The fuel spray prevention caps are
installed so that fuel will not spout over Check that two valves are inserted in holes
the hot part of the engine and catch fire (a) and (b).
when it leaks by any chance. 12.Install and tighten rocker arm assembly (76) with
mounting bolts (75).
a Check that the spherical portion of
adjustment screw (78) is fitted properly in the
socket of the push rod (79), and then tighten
50-36 PC360LC-10
2 Mounting bolt (75) and seat:

65 ± 5 Nm {6.63 ± 0.51 kgm}
14.After adjusting the valve clearance, install cap

(68).
13.Adjust the valve clearance. For details, see

Testing and adjusting, "Adjusting valve
clearance".
a Rotate the crankshaft in the normal direction
and bring stamp (a) of supply pump gear (69)
to the top to set the No. 1 cylinder to the
pump gear (69) since the view is narrow. 15.Install the gasket to rocker housing (73).
16.Install rocker housing (73) to the cylinder head.
17.Tighten the mounting bolts in the numeric order
([1] o [7]) shown in the figure.
with the wrench. 3 Mounting bolt:
3 Locknut: 24 ± 4 Nm {2.45 ± 0.41 kgm}
18.Install plate (72) to rocker housing (73).
24 ± 2.4 Nm {2.45 ± 0.24 kgm}
PC360LC-10 50-37
19.Install injector wiring harness (71). a Install wiring harness (71) so that it will not
strongly contact the inside wall of rocker
3 Capture nut:
housing (73), will not come off guide (u), or
24 ± 4 Nm {2.45 ± 0.41 kgm} will not be bent sharply.
a Tighten the capture nuts alternately. a Secure clearance (E) of at least 3 mm
a The capture nut cannot be removed from the between wiring harness (71) and rocker
wiring harness. housing (73).
a Installed positions of harnesses a Secure clearance (F) of at least 3 mm

between wiring harness (71) and rocker arm
(76).
1, 3, 5
q Orange reverse
2, 4, 6
s Brown reverse
20.Fit the gasket to head cover (67) and install

them to the rocker housing.
3 Mounting bolt:
12 ± 2 Nm {1.22 ± 0.2 kgm}
a Install injector wiring harness terminal (108) 21.Install blowby hose (66).
so that it will not interfere with rocker arm 22.Install hose clamp (65).
(76) when the rocker arm moves.
50-38 PC360LC-10
3 Mounting bolt:
24 ± 4 Nm {2.45 ± 0.41 kgm}
27.Tighten tube (58) and spacer (61) with U-bolt

(60).
23.Install KCCV inlet hose (64), and install KCCV a Measure distance (X) between the end of
crank pressure sensor mounting bracket (184). bellows of tube (58) and the top of the head
3 Hose clamp: cover.
3.9 to 4.9 Nm {0.4 to 0.5 kgm} • Distance (X): 220.5 ± 1 mm
24.Install KCCV outlet tube (63). 3 U-bolt fastening nut:
3 Hose clamp: 14.7 to 44.1 Nm {1.5 to 4.5 kgm}
3.9 to 4.9 Nm {0.4 to 0.5 kgm} 28.By using tool A12 (long socket), tighten V-clamp
25.Install tube clamp (62). (57) lightly.
• Width across flats of V-clamp fastening nut:
7/16 in (11.1 mm)
26.Before installing V-clamps (56) and (57), check

them for abnormality.
a V-clamp can be reused, however, replace it
with a new one in the following conditions.
• Deformation of V-clamp
• Damage on T-bolt thread portion
• Crack at V-groove
• Peeling at V-groove
29.Fit the gasket between the inlet flange of KDPF

assembly (109) and the flange of tube (58) and
check the clearance.
a Adjust the clearance to 5 mm or less all
around.
PC360LC-10 50-39
a When adjusting the clearance, loosen four

each of nuts (111) and (112) of U-bolt (110)
and move in the turning direction to adjust
finely.
a If the clearance cannot be adjusted finely in
the turning direction, loosen mounting bolts
(114) of KDPF mounting bracket (113) and
adjust by moving KDPF mounting bracket
(113).
30.By using tool A12 (long socket), tighten V-clamp
(56) lightly.
7/16 in (11.1 mm)
7/16 in (11.1 mm)
3 V-clamp fastening nut:
6.9 to 8.8 Nm {0.7 to 0.9 kgm}
7/16 in (11.1 mm)
6.9 to 8.8 Nm {0.7 to 0.9 kgm}
33.If nuts (111) and (112) of U-bolt (110) were
loosened, tighten evenly at the four places.
3 Four U-bolt fastening nuts (112):
31.4 ± 12.7 Nm {3.2 ± 1.3 kgm}
31.4 ± 12.7 Nm {3.2 ± 1.3 kgm}
34.If mounting bolts (114) of KDPF mounting
bracket (113) were loosened, tighten them.
35.Finger-tighten brackets (59) and (122) for KDPF
piping. a When tightening U-bolt fastening nuts (111)
36.Install tube (58) to KVGT piping bracket (59). and (112), install a spanner head to a
a Do not make clearance on the mounting interchangeable-head torque wrench to
face. tighten them.
2 Mounting bolt:
3 Mounting bolt:
78.5 to 88.5 Nm {8.0 to 9.0 kgm}
37.Tighten brackets (59) and (122) for KDPF piping
38.Install gasket (115) to air intake manifold cover

(116).
50-40 PC360LC-10
43.While installing the following connectors, wiring

harness clamp, and bracket, install engine wiring
harness (53).
• Ambient pressure sensor connector (46)
• Three wiring harness connectors (50)
• Common rail pressure sensor (51)
• Charge (boost) pressure and temperature
sensor connector (52)
• Two wiring harness clamps (47)
3 Mounting bolt:
24 ± 4 Nm {2.45 ± 0.41 kgm}
• Bracket (48)
39.If intake air heater (117) and air intake connector
(118) were removed from the air intake manifold, 3 Mounting bolt:
install them according to the following 24 ± 4 Nm {2.45 ± 0.41 kgm}
procedure.
1) Install guides [1] longer than 150 mm to two
upper bolt holes (A).
2) Install gasket (119), plate (120), gasket (119),
intake air heater (117), gasket (119), and air
intake connector (118) in order.
3) Install two lower bolts (121) and fingertighten
them.
4) Remove guides, install remaining two bolts
(121), and fingertighten them.
5) Tighten four bolts (121) to the specified
torque.
3 Mounting bolt:
24 ± 4 Nm {2.45 ± 0.41 kgm}
6) Install the wiring terminal to portion (E) of
intake air heater (117).
40.Install the air intake manifold (55).

3 Mounting bolt:
24 ± 4 Nm {2.45 ± 0.41 kgm}
41.Install cover (54), and install hose clamp (183)
and wiring harness clamp (182) so that their
angle is as shown in the figure.
42.Install sandwich clamp (49) of the injection pipe
to the air intake manifold.
3 Mounting bolt:
24 ± 4 Nm {2.45 ± 0.41 kgm}
PC360LC-10 50-41
3 Hose clamp:
10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}
50.Install wiring harness bracket (37).
3 Mounting nut:
24 ± 4 Nm {2.45 ± 0.41 kgm}
51.Install hoses (38) and (39) coming from the
KVGT.
• Hose (38): KVGT control pressure circuit
• Hose (39): KVGT actuator drive pressure
circuit
3 Sleeve nut (38):
44.Fit a new gasket to the air intake manifold and
25 ± 1.5 Nm {2.55 ± 0.15 kgm}
install EGR valve (43).
3 Sleeve nut (39):
3 Mounting bolt:
15 ± 1 Nm {1.53 ± 0.1 kgm}
43 ± 6 Nm {4.38 ± 0.61 kgm}
52.Install wiring harness connectors (34), (35), and
45.Install tube (45).
(36).
3 Sleeve nut: • Connector (34): KVGT position sensor
25 ± 1.5 Nm {2.55 ± 0.15 kgm} • Connector (35): KVGT speed sensor
• Connector (36): Connector box
53.Install EGR orifice temperature sensor
connector (33).
46.Install tube (44) under EGR valve (43).

3 Sleeve nut:
25 ± 1.5 Nm {2.55 ± 0.15 kgm} • Carry out the rest of installation in the reverse
order to removal.
[*1]
3 Hose clamp:
10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}
14.7 to 44.1 Nm {1.5 to 4.5 kgm}
[*2]
a Adjust the air conditioner compressor belt
tension. For details, see Testing and adjusting,
"Testing and adjusting air conditioner
compressor belt tension".
47.Install the hose portion of EGR valve piping (32)
to tube (42). [*3]
48.Fit the gasket and install EGR valve piping (32). 3 Air conditioner compressor assembly
3 Mounting bolt: mounting bolt:
24 ± 4 Nm {2.45 ± 0.41 kgm} 10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}
49.Tighten hose clamp (41) to the specified torque. [*4]
50-42 PC360LC-10

10.8 to 26.5 Nm {1.1 to 2.7 kgm}
[*5]
a Use new MIKALOR clamps.
2 Clamp bolt thread portion (BC):
Lubricant oil (ThreeBond PANDO 18B or
equivalent)
hose.
3 Clamp bolt:
16 to 17 Nm {1.6 to 1.7 kgm}
to 7 mm.
[*6]
3 Intake air heater connector E01:
4.0 ± 0.6 Nm {0.41 ± 0.15 kgm}
• Checking for fuel leakage (fuel system)
Check the fuel system for leakage. For details,
see Testing and adjusting, "Checking fuel
system for leakage".
• Bleeding air (fuel system)
system".
PC360LC-10 50-43
Removal and installation of cylinder head assembly (PC300-A100-924-K-00-A)

Necessity
Symbol
Q'ty
Part No. Part name
assembly (9).
4 795-799-6700 Puller t 1 direction of belt (12).
A 5 795-799-8150 Remover q 1 3) Remove loosened air conditioner
Wrench (angle) compressor belt (12). [*2]
6 790-331-1120 q 1
4) Remove four mounting bolts (13), disconnect
7 795-790-4510 Gauge q 1
air conditioner compressor assembly (9)
k Turn the battery disconnect switch to the from bracket (11), and move it to a place
OFF position and remove the key. where it is not an obstacle to the work. [*3]
Removal (PC300-A100-520-K-00-A)

tank.
from the KVGT. [*1]

assembly".
6. Remove step (5).

50-44 PC360LC-10


machine, remove bolts (19), and disconnect
receiver (20) and bracket together.
(17).
slantways so that it will not interfere with
frame (A).


vinyl sheet etc.

PC360LC-10 50-45
21.Disconnect intake air heater E01 (26) and wiring 32.Disconnect tube (44) under EGR valve (43).
25.Remove base bracket (31).
33.Disconnect tube (45).

34.Remove EGR valve (43).
26.Disconnect EGR orifice temperature sensor

connector (33) of EGR valve piping (32).
27.Disconnect wiring harness connectors (34), (35),
and (36).
28.Disconnect wiring harness bracket (37).
k When disconnecting the hoses, always 35.Disconnect ambient pressure sensor (46).
disconnect at the intake manifold side to 36.Disconnect wiring harness clamp (47) and
avoid splashing oil to high temperature bracket (48).
area which causes fire. 37.Remove sandwich clamp (49) of the injection
pipe.
• Hose (38): KVGT control pressure circuit 38.Disconnect two wiring harness connectors (50).
• Hose (39): KVGT actuator drive pressure
circuit a Disconnect the remaining one connector
30.Remove four mounting bolts (40) to remove after removing the blowby hose.
EGR valve piping (32). 39.Disconnect common rail pressure sensor (51).
31.Loosen hose clamp (41) of EGR valve piping 40.Disconnect charge (boost) pressure and
(32) and remove it from tube (42). temperature sensor connector (52).
the work.
42.Disconnect hose clamp (183) and wiring
harness clamp (182), and remove cover (54).
50-46 PC360LC-10
43.Remove air intake manifold (55).
50.Disconnect radiator hose clamps (128) and

(129).
51.Disconnect radiator hoses (130) and (131).
52.Disconnect exhaust manifold pressure sensor
connector (132).
53.Disconnect wiring harness clamp (133).
44.Remove engine hood assembly (125). For

details, see "Removal and installation of engine
hood assembly".
45.Remove KDPF assembly (126). For details, see
"Removal and installation of KDPF assembly".
46.Disconnect tube clamp (62).
47.Remove KCCV outlet tube (63). 54.Remove hoses (135) and (136) from KVGT
(134).
a Remove the hoses at both ends of tube (63) 55.Remove hose (135) from connector block (181).
together.
48.Remove KCCV crank pressure sensor mounting
bracket (184), and remove KCCV inlet hose
(64).
PC360LC-10 50-47
56.Disconnect tube (136) from tube (137). 64.Disconnect tube (146).

57.Disconnect tube clamp (138) to remove tube 65.Loosen hose clamp (147) and disconnect tube
(136). (148).
58.Disconnect aftercooler tube (139) from KVGT 66.Remove four nuts (149), then sling and remove
(134). KVGT (134).
a One of nuts (149) is tightened on the
underside.
4 KVGT:
30 kg
67.Disconnect hoses (151) and (152) from EGR
cooler (150).
68.Remove bracket (154), connector block (181),
and hoses (151) and (152) together from
exhaust manifold (153).

60.Remove two tube clamp nuts (141).
61.Loosen hose clamp (142) and remove tube
(137).
62.Remove tube (143) and bracket (144).

63.Remove tube mounting bolt (145) and remove
tube (42) from EGR cooler (150).
69.Remove mounting bolt (155), then disconnect

EGR cooler (150) and exhaust manifold (153).
a When disconnecting, take care that the
gasket will not fall.
50-48 PC360LC-10
70.Remove tube (156) under the EGR cooler.

71.Remove EGR cooler (150) from EGR mounting
bracket (180).
72.Remove exhaust manifold (153).
a When disconnecting, take care that the
gasket will not fall.

78.Disconnect blowby hose (66).
79.Disconnect harness connector (50) and move
engine wiring harness (53) to a place where it is
not an obstacle to the work.
80.Disconnect tube clamps (162) and (163).
81.Remove head cover (67).
73.Remove plate (157).
82.Loosen and remove cap (68) of the front gear

74.Remove fan guard (158). cover.
75.Disconnect radiator hose (159).
76.Disconnect wiring harness clamps (160) and

83.Rotate the crankshaft in the normal direction
(161).
and bring stamp (a) of supply pump gear (69) to
the top to set the No. 1 cylinder to the
PC360LC-10 50-49

with the wrench.
87.Remove 12 mounting bolts (75) to remove

88.Remove 12 push rods (79).
89.Remove crossheads (80).
84.Loosen the capture nut at the injector head and a Record the installed positions and directions
disconnect injector wiring harness (71). of the crossheads (shapes of holes at
a Loosen the capture nuts alternately. portions (a) and (b)). (Reinstall them in the
same directions)
wiring harness.
1, 3, 5
q Orange reverse
2, 4, 6
s Brown reverse
85.Loosen lock nuts (77) and then loosen
adjustment screws (78) two to three turns each
so that the valve spring tension will not be
applied to rocker arm mounting bolts (75).
86.Remove mounting bolts (74) to remove rocker 90.Remove 14 fuel spray prevention caps (88) of
housing (73). high-pressure pipe (87) and injection pipes (81)
to (86).
91.Remove sandwich clamp (89) of high-pressure
pipe (87) and injection pipes (81) to (86).
a Take care that sandwich clamps will not fall.
92.Remove high-pressure pipe (87) and injection
pipes (81) to (86).
50-50 PC360LC-10
93.Remove retaining nut (90) and remove inlet

connector (91).
a Before removing retaining nut (90), remove 98.Remove mounting bolts (98), (99), and (100) to
all soil, sand, etc. sticking around it. remove common rail (97).
a Use tool A5 to remove inlet connector (91).
94.Remove holder mounting bolt (92).
95.By using tool A4, remove holder (93) and
injector assembly (94) together.
a Take care that dirt and foreign material will
not enter the injector mounting bore.
a Never grip the solenoid valve on the top of
the injector with pliers etc.

100.Remove hose (167).
a The connector of hose (167) is fitted with the
rubber cap. Push the lock from over the
rubber cap to remove the hose.
101.Remove mounting bolts (169) to disconnect
fuel filter bracket (168).
102.Remove bolts (170) and (171) to remove

bracket (172) form the supply pump.
PC360LC-10 50-51
103.Remove 26 mounting bolts (173) to remove 2. Sling cylinder head assembly (174) and install it
cylinder head assembly (174). to the cylinder block.
a Check that the half collet is fitted securely to
4 Cylinder head assembly:
the groove of the valve stem by hitting the
95 kg valve stem lightly with a plastic hammer.
4 Cylinder head assembly:

95 kg
104.Remove cylinder head gasket (175).
3. Before installing the cylinder head bolts, check

the following conditions. If any bolt is applicable,
do not use it but replace it with a new one.
• The bolt has been tightened six times (has
five punch marks of number of tightening).
• Stem length (a) of bolt: 162.6 mm or above
(Measure the length by using tool A7.)
Installation (PC300-A100-720-K-00-A)
1. Install cylinder head gasket (175) to the cylinder

block.
a Check that the cylinder head mounting face
and inside of the cylinders are free from dirt
and foreign material.
a Match the holes of cylinder head gasket
(175) with those of the cylinder block.
a When installing the cylinder head gasket, 4. Tighten the cylinder head mounting bolts in the
check that the grommets are not fall off or following procedure.
lost.
50-52 PC360LC-10
1) Install each cylinder head mounting bolt and 3) Tighten mounting bolt (171) on the supply
tighten it at least two to three turns with the pump flange side.
hand at first.
2 Cylinder head mounting bolt: 77 ± 12 Nm {7.85 ± 1.22 kgm}
2) Tighten in the order of [1] to [26] shown in the
figure.
3 Cylinder head mounting bolt:
1] 50 ± 7 Nm {5.1 ± 0.71 kgm}
2] 150 ± 10 Nm {15.3 ± 1.02 kgm}
3] Return all the bolts 360 deg.
4] 115 ± 5 Nm {11.7 ± 0.5 kgm}
5] Check the torque of 115 ± 5 Nm {11.7 ±
0.5 kgm}
6] 120 ± 5 deg. (Tighten with angle
tightening tool A6)
6. Install fuel filter bracket (168) with mounting bolt
(169).
7. Install hose (167).
a Ensure that mud or dirt is not sticking to the
hose joint portions.
8. Install tube (166).
3 Sleeve nut:
24 ± 4 Nm { 2.45 ± 0.41 kgm}
• When angle tightening tool A6 is not used

Make marks on the cylinder head and
bolt with a paint, etc., then retighten the
bolt by 120 ± 5 deg.
9. Install the injector assembly according to the

a Check that the injector mounting bore is free
from flaw, dirt, etc.
a When replacing the injector with a new one,
be sure to replace the inlet connector with a
new one, as well.
5. Install supply pump bracket (172) to the cylinder 1) Check inlet connector (91) visually. If it has
head according to the following procedure. any of the following faults, replace it.
1) Tighten bolts (170) and (171) of bracket 1] There is a burr or a worn part at front end
(172) lightly. (a) or rear end (b) of the inlet connector.
2) Tighten mounting bolt (170) on the cylinder 2] There is foreign material in the edge filter
head side. at rear end (c) of the inlet connector.
3] The O-ring at top (d) of the inlet connector
3 Mounting bolt (170): is cracked or deteriorated.
43 ± 6 Nm {4.38 ± 0.61 kgm}
PC360LC-10 50-53
4] There is a worn part or an uneven seat 4) Insert injector (94) into the cylinder head with
contact mark on seat face (e) at the front the fuel inlet toward the air intake manifold.
end of the inlet connector. 5) Fingertighten mounting bolts (92) of holder
(93) three to four turns.
a If high-pressure fuel leaks through the
inlet connector, the seat face has fine
streaks or flaws. If any of these
phenomena is detected, replace the inlet
connector and injector.
6) Tighten inlet connector (91) lightly with

retaining nut (90).
2 O-ring of inlet connector (91) and
mounting hole on cylinder head
side:
a After tightening lightly as above, tighten to
the specified torque. Be sure to tighten
each bolt and nut to the respective
specified torques. If a bolt or a nut is
tightened insufficiently or too strongly,
fuel may leak into the engine.
3 Retaining nut (90) (tightening
lightly):
15 ± 5.0 Nm {1.53 ± 0.51 kgm}
2) Fit gasket (95) and O-ring (96) to fuel injector

(94).
2 O-ring (96) of injector (94) and
injector mounting hole:
3) Install holder (93) to injector (94).
a Match concave (A) and convex (B)
portions with each other.
7) Tighten mounting bolts (92) of holder (93)

alternately.
10 ± 2 Nm {1.02 ± 0.2 kgm}
a The top of holder (93) must be in parallel
with the top of the cylinder head.
• Max. allowable angle: 2.4 deg
8) Tighten inlet connector (91) with retaining nut
50-54 PC360LC-10
2 Retaining nut (90) and "f" (hatched 5) Do not reuse the seal washer but replace
portion) in figure of cylinder head: with a new one.
GE TOSHIBA SILICONES 6) Install pressure limiter (176) and new seal
TOSSEAL381 washer.
3 Retaining nut (90): a Apply clean gear oil (#90) to the threaded
portion.
50 ± 4 Nm {5 ± 0.4 kgm}
7) Tighten pressure limiter (176) to the specified
torque.
3 Tightening torque:
27 ± 4 Nm {2.75 ± 0.41 kgm}
8) After tightening to the specified torque,
tighten again.
3 Retightening angle:
90 ± 5 deg.
9) After starting the engine, check that fuel does
not leak.
a For the testing procedure, see Testing
and adjusting, "Testing fuel system for
leakage".
10.If pressure limiter (176) is removed from

common rail (97), perform the following
procedure.
a Do not remove common rail pressure sensor
(177). (If it was removed, replace it together
with common rail (97) as a unit.)
1) Before removing pressure limiter (176),
remove mud, etc. from around it thoroughly
and clean it.
2) Check that there is no damage on the high-
pressure fuel sealing surfaces on pressure
limiter (176) and common rail (97).
3) Check that there is no damage on adapter
(178) of pressure limiter (176). 11.Install the high-pressure pipe and injection pipe
a When tightening adapter (178) after
removing it, use new copper seal washer
(179) and apply gear oil (#90).
3 Tightening torque:
37 ± 4 Nm {3.77 ± 0.41 kgm} k Be sure to use the genuine clamp for the
4) If pressure limiter (176) has fuel leakage high-pressure pipe and injection pipe,
more than the specified value, do not reuse it and observe the specified tightening
but replace it with a new one. torque.
PC360LC-10 50-55
k Install each high-pressure pipe or

injection pipe and wiring harness at least
10 mm apart from each other.
a A high-pressure pipe or injection pipe may
cause fuel leakage if visible lengthwise slits
(b) or dents (c) are found at the joint's taper
seal at part (a) (within 2 mm from the end), or
the stepped wear at part (d) (2 mm from the
end of taper seal) is as severe as it can be
felt with a fingernail. If there is any of these
defects, replace the high-pressure pipe or
injection pipe.
4) Tighten high-pressure pipes (81) to (86)
between the inlet connector and common
rail.
3 Sleeve nut:
37 ± 4 Nm {3.77 ± 0.41 kgm}
5) Tighten common rail mounting bolts (98),
(99) and (100).
3 Mounting bolt:
1) Check that inlet connector (91) is fastened by 43 ± 4 Nm {4.38 ± 0.41 kgm}
torque. (6 places)
50 ± 4 Nm {5 ± 0.4 kgm}
2) Set common rail (97) and mounting bolts (98),
(99) and (100), then finger-tighten the
mounting bolts.
6) Tighten the bracket of the sandwich clamp

which is fixing high-pressure pipe (87) and
injection pipes (81) to (86).
a Install bracket (105) of high-pressure pipe
#2 (82) on bracket (106) and tighten it
with bolt (103).
a Tighten bracket (49) of high-pressure
3) Tighten high-pressure pipe (87) between the pipe #3 (83) with bolt (107) after installing
supply pump and common rail. air intake manifold (55).
a Width across flats of sleeve nut 3 Mounting bolts (101) to (104),
Supply pump side: 19 mm (107):
Common rail side: 22 mm 24 ± 4 Nm { 2.45 ± 0.41 kgm}
7) Tighten sandwich clamp (89).
3 Sleeve nut:
3 Mounting bolt:
37 ± 4 Nm {3.77 ± 0.41 kgm}
6 Nm {0.61 kgm}
8) Install 14 fuel spray prevention caps (88).
50-56 PC360LC-10
a Set the slits of each bellows out and

down.
a The fuel spray prevention caps are
installed so that fuel will not spout over
the hot part of the engine and catch fire
when it leaks by any chance.
12.Install push rod (79).

Check that push rod (79) is in the tappet.
2 Push rod socket:
13.Install crosshead (80).
a When reusing the crosshead, install the
same intake and exhaust valves in the same
direction because the shapes of its holes (a)
and (b) are different. (A new crosshead may
be installed in either direction.)
Check that two valves are inserted in holes
(a) and (b).
14.Install rocker arm assembly (76) and tighten it
with mounting bolts (75).
a Check that the spherical portion of
adjustment screw (78) is fitted properly in the
socket of the push rod (79), and then tighten
2 Mounting bolt (75) and seat:
65 ± 5 Nm {6.63 ± 0.51 kgm}
9) Install tube (165).

3 Joint bolt (165):
24 ± 4 Nm { 2.45 ± 0.41 kgm}
10)Install tube (164).
3 Joint bolt (164):
24 ± 4 Nm { 2.45 ± 0.41 kgm}
PC360LC-10 50-57
17.Install the gasket to rocker housing (73).

15.Adjust the valve clearance. For details, see
18.Install rocker housing (73) to the cylinder head.
Testing and adjusting, "Adjusting valve
19.Tighten mounting bolts (74) in the numeric order
clearance".
([1] o [7]) shown in the figure.
a Rotate the crankshaft in the normal direction
and bring stamp (a) of supply pump gear (69)
to the top to set the No. 1 cylinder to the 24 ± 4 Nm { 2.45 ± 0.41 kgm}
with the wrench.
3 Locknut:
24 ± 2.4 Nm {2.45 ± 0.24 kgm}
20.Install injector wiring harness (71).

3 Capture nut:
24 ± 4 Nm { 2.45 ± 0.41 kgm}
a Tighten the capture nuts alternately.
wiring harness.
16.After adjusting the valve clearance, install cap

(68).
50-58 PC360LC-10
Cable color Cylinder No. a Secure clearance (F) of at least 3 mm

p Yellow May be installed in between wiring harness (71) and rocker arm
1, 3, 5 (76).
q Orange reverse
2, 4, 6
s Brown reverse
21.Fit the gasket to head cover (67) and install

them to the rocker housing.
3 Mounting bolt:
a Install injector wiring harness terminal (108)
so that it will not interfere with rocker arm 12 ± 2 Nm {1.22 ± 0.2 kgm}
(76) when the rocker arm moves. 22.Install blowby hose (66).
23.Install hose clamp (65).
3 Mounting bolt:
24 ± 4 Nm { 2.45 ± 0.41 kgm}
24.Install wiring harness clamps (160) and (161).
a Install wiring harness (71) so that it will not

strongly contact the inside wall of rocker
housing (73), will not come off guide (U), or
will not be bent sharply.
a Secure clearance (E) of at least 3 mm 25.Install fan guard (158).
between wiring harness (71) and rocker 26.Install radiator hose (159).
housing (73). 3 Hose clamp:
10.8 to 11.8 Nm {1.1 to 1.2 kgm}
PC360LC-10 50-59
27.Install plate (157).

3 Mounting bolt:
43 ± 6 Nm {4.38 ± 0.61 kgm}
33.Install a new gasket to the exhaust manifold.

34.Sling and install KVGT (134), while inserting
tube (148) into the hose.
28.Fit a new gasket and install exhaust manifold 4 KVGT:

(153) according to the following procedure. 30 kg
1) Tighten all the bolts in the order of [1] to [12] 35.Tighten mounting nuts (149) of KVGT (134) and
shown in the figure. hose clamp (147).
3 Mounting bolt: a Tighten one of nuts (149) on the underside.
53 ± 5 Nm {5.4 ± 0.51 kgm} 3 Mounting nut:
2) Retighten only bolts [1] to [4] shown in the
figure in that order. 55 ± 6 Nm {5.61 ± 0.61 kgm}
3 Mounting bolt: 3 Hose clamp:

53 ± 5 Nm {5.4 ± 0.51 kgm} 5 ± 1 Nm {0.51 ± 0.1 kgm}
29.Install EGR cooler (150) to exhaust manifold 36.Tighten tube (146).
(153) and EGR mounting bracket (180) and 37.If connector block (181) and bracket (154) were
fingertighten it. disconnected, connect them.
30.Tighten mounting bolts (155) of EGR cooler 3 Mounting bolt:
(150) and exhaust manifold (153). 24 ± 4 Nm { 2.45 ± 0.41 kgm}
3 Mounting bolt: 38.Install bracket (154) installed with connector
43 ± 6 Nm {4.38 ± 0.61 kgm} block (181) and hoses (151) and (152) to
31.Tighten EGR cooler (150) and EGR mounting exhaust manifold (153).
bracket (180) to the specified torque. 3 Mounting bolt:
32.Install tube (156). 43 ± 6 Nm {4.38 ± 0.61 kgm}
3 Mounting bolt: 39.Install hoses (151) and (152) to EGR cooler
9.5 ± 2 Nm {0.97 ± 0.2 kgm} (150).
3 Hose clamp: 3 Sleeve nut:

8.8 ± 0.5 Nm {0.9 ± 0.05 kgm} 15 ± 1 Nm {1.53 ± 0.1 kgm}
50-60 PC360LC-10

3 Hose clamp (142):
5 ± 1 Nm {0.51 ± 1 kgm}
3 Two mounting nuts (141):
10 ± 2 Nm {1.02 ± 0.2 kgm}
3 Mounting bolt (EGR cooler side):
24 ± 4 Nm { 2.45 ± 0.41 kgm}
3 Joint bolt (upper side of tube):
40 ± 5 Nm {4.08 ± 0.51 kgm}
40.Tighten mounting bolt (145) of tube (42) lightly.
41.Fit gasket and install tube (42) to EGR cooler 3 Sleeve head (lower side of tube):
(150). 35 ± 5 Nm {3.57 ± 0.51 kgm}
3 Mounting bolt:
24 ± 4 Nm { 2.45 ± 0.41 kgm}
42.Tighten mounting bolts (145) of tube (42) to the
specified torque.
3 Mounting bolt:
43 ± 6 Nm {4.38 ± 0.61 kgm}
43.Install bracket (144).
3 Mounting bolt:
43 ± 6 Nm {4.38 ± 0.61 kgm}
3 Sleeve nut (bracket side): 47.Install tube (136) to tube (137).
24.5 ± 9.5 Nm {2.5 ± 0.97 kgm}
3 Sleeve nut:
3 Sleeve nut (exhaust manifold side): 35 ± 5 Nm {3.57 ± 0.51 kgm}
18 ± 3 Nm {1.84 ± 0.31 kgm} 48.Install tube clamp (138).
3 V-clamp:
7 ± 1 Nm {0.7 ± 0.1 kgm}
PC360LC-10 50-61
3 Joint bolt:
40 ± 4 Nm {4.08 ± 0.41 kgm}

tube (139) according to the following
procedure. 52.Install exhaust manifold pressure sensor
a Use new MIKALOR clamps. connector (132).
53.Install wiring harness clamp (133).
a Impact wrench is not allowed to use. 54.Install radiator hoses (130) and (131).
a With bridge (BR) set under the clamp bolt, 55.Install radiator hose clamps (128) and (129).
tighten the bolt so that bridge (BR) laps over
with the band by dimension (b) indicated
below.
Lubricant oil (ThreeBond PANDO 18B
or equivalent)
Install the clamp to the clamp mark put on
the hose.
3 Clamp bolt:
16 to 17 Nm {1.6 to 1.7 kgm} 56.Install frame (127).
Tighten the clamp so that dimension (BDG)
is 4 to 7 mm.
57.Install KCCV inlet hose (64), and install KCCV

crank pressure sensor mounting bracket (184).
3 Hose clamp:
50.Install hose (135) to connector block (181). 3.9 to 4.9 Nm {0.4 to 0.5 kgm}
58.Install KCCV outlet tube (63).
3 Sleeve nut:
36 ± 4 Nm {3.67 ± 0.41 kgm} 3 Hose clamp:
51.Install hoses (135) and (136) to KVGT (134). 3.9 to 4.9 Nm {0.4 to 0.5 kgm}
Put gaskets between hoses (135) and (136) and 59.Install tube clamp (62).
KVGT (134).
50-62 PC360LC-10
60.Install KDPF assembly (126). For details, see

"Removal and installation of KDPF assembly".
61.Install engine hood assembly (125). For details,
see "Removal and installation of engine hood
assembly".
64.Install the air intake manifold (55).

3 Mounting bolt:
24 ± 4 Nm {2.45 ± 0.41 kgm}
65.Install cover (54), and install hose clamp (183)
and wiring harness clamp (182) so that their
62.Fit gasket (115) to air intake manifold cover angle is as shown in the figure.
(116). 66.Install sandwich clamp (49) of the injection pipe
to the air intake manifold.
3 Mounting bolt:
24 ± 4 Nm {2.45 ± 0.41 kgm}
67.While installing the following connectors, wiring
harness clamp, and bracket, install engine wiring
harness (53).
• Ambient pressure sensor connector (46)
• Three wiring harness connectors (50)
• Common rail pressure sensor (51)
• Charge (boost) pressure and temperature
sensor connector (52)
• Two wiring harness clamps (47)
63.If intake air heater (117) and air intake connector
(118) were removed from the air intake manifold, 3 Mounting bolt:
install them according to the following 24 ± 4 Nm {2.45 ± 0.41 kgm}
procedure. • Bracket (48)
1) Install guides [1] longer than 150 mm to two
3 Mounting bolt:
upper bolt holes (A).
2) Install gasket (119), plate (120), gasket (119), 24 ± 4 Nm {2.45 ± 0.41 kgm}
intake air heater (117), gasket (119), and air
intake connector (118) in order.
3) Install two lower bolts (121) and fingertighten
them.
4) Remove guides [1], install remaining two
bolts (121), and fingertighten them.
5) Tighten four bolts (121) to the specified
torque.
3 Mounting bolt:
24 ± 4 Nm {2.45 ± 0.41 kgm}
6) Install the wiring terminal to portion (E) of
intake air heater (117).
PC360LC-10 50-63
70.Install tube (44) under EGR valve (43).

3 Sleeve nut:
25 ± 1.5 Nm {2.55 ± 0.15 kgm}
71.Install the hose portion of EGR valve piping (32)

to tube (42).
72.Fit the gasket and install EGR valve piping (32).
3 Mounting bolt:
24 ± 4 Nm { 2.45 ± 0.41 kgm}
73.Tighten hose clamp (41) to the specified torque.
3 Hose clamp:
68.Fit a new gasket to the air intake manifold and 10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}
install EGR valve (43). 74.Install wiring harness bracket (37).
3 Mounting bolt: 3 Mounting nut:

43 ± 6 Nm {4.38 ± 0.61 kgm} 24 ± 4 Nm { 2.45 ± 0.41 kgm}
69.Install tube (45). 75.Install hoses (38) and (39) coming from the
KVGT.
3 Sleeve nut: • Hose (38): KVGT control pressure circuit
25 ± 1.5 Nm {2.55 ± 0.15 kgm} • Hose (39): KVGT actuator drive pressure
circuit
3 Sleeve nut (38):
25 ± 1.5 Nm {2.55 ± 0.15 kgm}
3 Sleeve nut (39):
15 ± 1 Nm {1.53 ± 0.1 kgm}
76.Install wiring harness connectors (34), (35), and
(36).
50-64 PC360LC-10
77.Install EGR orifice temperature sensor 3 Clamp bolt:

connector (33). 16 to 17 Nm {1.6 to 1.7 kgm}
to 7 mm.

order to removal.
[*1]
3 Hose clamp: [*6]
10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}
3 U-bolt mounting nut: 4.0 ± 0.6 Nm {0.41 ± 0.15 kgm}
14.7 to 44.1 Nm {1.5 to 4.5 kgm} • Checking for fuel leakage (fuel system)
[*2] Check the fuel system for leakage. For details,
a Adjust the air conditioner compressor belt
tension. For details, see Testing and adjusting,
[*3] system".
3 Air conditioner compressor assembly
mounting bolt:
10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}
[*4]
10.8 to 26.5 Nm {1.1 to 2.7 kgm}
[*5]
equivalent)
hose.
PC360LC-10 50-65
Removal and installation of radiator assembly (PC220-B220-924-K-00-A)
7. Disconnect hose clamps (9), (10), and (11).

8. Disconnect radiator hoses (12), (13), (14), and
k Turn the battery disconnect switch to the
(15). [*2]
OFF position and remove the key.
Removal (PC300-B220-520-K-00-A)
1. Remove undercover (1).

machine and remove cover (16) and frame (17).
2. Drain the coolant through drain valve (2). (Drain

hose: inside diameter f7 mm)
6 Coolant:
37 l
10.Pull out reservoir tank hose (7) from cover (18).

3. Disconnect radiator hose (3). [*1]

4. Remove four cover mounting bolts (4) to remove
cover (5).
12.Remove mounting bolts (19) so that hydraulic oil

cooler inlet tube (20) can be moved easily.
5. Open engine hood (6).

6. Open hose clamp (8) and disconnect reservoir
tank hose (7) from the radiator.
50-66 PC360LC-10
13.Disconnect hydraulic oil cooler inlet tube (20). 18.Sling and remove radiator assembly (30). [*3]
14.Remove seven mounting bolts (21) to remove
a Sling and remove radiator assembly (30). [*3]
bracket (22).
15.Remove three mounting bolts (23) to remove
4 Radiator assembly:
bracket (24).
16.Remove four wing nuts (25) to remove nets (26) 35 kg
and (27).
Installation (PC300-B220-720-K-00-A)
• Perform installation in the reverse order to

removal.
[*1] [*2]
17.Remove four mounting bolts (28) to remove • Dimension (b): Min. 5 mm
cover (29).
equivalent)
hose.
3 Clamp bolt:
2.9 to 5.9 Nm {0.3 to 0.6 kgm}
PC360LC-10 50-67

to 7 mm.
3 Radiator hose clamp:

10.8 to 11.8 Nm {1.1 to 1.2 kgm}
[*3]
a Make sure that the insulation seal (sponge) at
the radiator periphery is not damaged.
a If the heat insulation seal (sponge) is damaged,
replace it.
a When installing the radiator assembly, carefully
lower it to avoid the insulation seal (sponge) at
the periphery from being damaged.
a Check that the convexed parts (A) at the bottom
of the radiator properly fits with the concaved
parts (B) of the machine from the undercover
side.
• Refilling of coolant
Supply coolant through the coolant filler to the
specified level. Run the engine to circulate the
coolant through the system. Then, check the
coolant level again.
5 Coolant:
37 l
50-68 PC360LC-10
Removal and installation of hydraulic oil cooler assembly (PC220-B8P0-924-K-00-A)
a Special tools a If using tool R1 and R2, remove the hydraulic

tank strainer and stop oil with tool R1 and
Necessity
Symbol
R2.
Q'ty
Part No. Part Name
1 796-460-1210 Oil stopper q 1

R
2 796-770-1320 Adapter q 1
k Park the machine on a level ground, lower

the work equipment to the ground stably, and
stop the engine.
k Set the lock lever in the LOCK position.
k Release the remaining pressure in the

hydraulic circuit. For details, see Testing and
adjusting, "Releasing remaining pressure 3. Open the side cover on the right side of the
from hydraulic circuit". machine, remove mounting bolts (5) so that
hydraulic oil cooler inlet tube (6) can be moved
k Turn the battery disconnect switch to the easily.
Removal (PC300-B8P0-520-K-00-A)
1. Remove undercovers (1), (2), and (3).
4. Remove mounting bolts (7) so that hydraulic oil

cooler outlet tube (8) can be moved easily.
2. Remove drain plug (4) to drain oil from the

hydraulic tank.
6 Hydraulic tank:
365 l
5. Remove three mounting bolts (24), then remove

cover (25) under the hydraulic oil cooler.
PC360LC-10 50-69
6. Remove plug (9) of hydraulic oil cooler outlet 11.Pull out reservoir tank hose (12) from cover (15).
tube (8) to drain the remaining oil. 12.Remove cover (15).
a After draining the oil, close plug (9).
7. Disconnect hydraulic oil cooler outlet tube (8).
13.Disconnect hydraulic oil cooler inlet tube (6).

14.Remove seven mounting bolts (16) to remove
bracket (17).
8. Open engine hood (10).
15.Remove four wing nuts (18) to remove nets (19)
9. Open hose clamp (11) and disconnect reservoir
and (20).
tank hose (12) from the radiator.
16.Remove two mounting bolts (21) and cushion

10.Remove cover (13) and frame (14).
(22).
a One bolt (23) is hidden behind cushion (22).
17.Remove three mounting bolts (23) and
disconnect the frame and hydraulic oil cooler.
50-70 PC360LC-10
a If the heat insulation seal (sponge) is damaged,

replace it.
a When installing the hydraulic oil cooler assembly,
carefully lower it to avoid the insulation seal
(sponge) at the periphery from being damaged.
a Check that the convex parts (A) at the bottom of
the hydraulic oil cooler properly fits with the
concave parts (B) of the machine from the
underside.
18.Remove four mounting bolts (24), then remove

cover (25).
• Refilling of oil
a Before supplying oil, make sure that the oil
cooler drain plug is securely tightened.
19.Sling and remove hydraulic oil cooler assembly a Add hydraulic oil through the oil filler port to
(26). [*1] the specified level. Run the engine to
circulate the oil through the piping. Then,
a Carefully lift the hydraulic oil cooler assembly check the oil level again.
so that its lower part is not caught.
5 Hydraulic tank:
4 Hydraulic oil cooler assembly: 365 l
45 kg
Installation (PC300-B8P0-720-K-00-A)

removal.
[*1]
a Make sure that the insulation seal (sponge) at
the hydraulic oil cooler periphery is not
damaged.
PC360LC-10 50-71
Removal and installation of aftercooler assembly (PC220-A9A0-924-K-00-A)
Removal (PC300-A9A0-520-K-00-A)
Installation (PC300-A9A0-720-K-00-A)
1. Open the engine hood and side cover on the
right side of the machine and remove cover (1)
removal.
and frame (2).
[*1]
2. Disconnect hoses (3) and (4) from aftercooler
assembly (5). [*1] a Tighten the MIKALOR clamps at both ends of
a MIKALOR clamp
a Put a mark of the hose end on the tube so
that the original position of the hose can be a Impact wrench is not allowed to use.
indicated.
equivalent)
hose.
3 Clamp bolt:
16 to 17 Nm {1.6 to 1.7 kgm}
to 7 mm.
3. Set slings to aftercooler assembly (5) and

remove four mounting bolts (6).
4. Sling and remove aftercooler assembly (5).
4 Aftercooler assembly:
25 kg
50-72 PC360LC-10
Removal and installation of engine and main pump assembly (PC300-R400-924-K-

00-A)
a Special tools
Necessity
Symbol
Q'ty
Part No. Part name
A 11 795-799-9300 Lifting tool q 1

1 796-460-1210 Oil stopper q 1
R
2 796-770-1320 Adapter q 1
k Park the machine on a level surface, lower

the work equipment to the ground so that it
is stable, and stop the engine.
6. Remove step (5).
k Set the lock lever in the Lock position. 7. Remove frames (6).
k Release the remaining pressure in the 9. Disconnect solenoid clutch connector AC03 (8)
hydraulic circuit. For details, see Testing and of the air conditioner compressor.
adjusting, "Releasing remaining pressure 10.Remove air conditioner compressor (9)
from hydraulic circuit". according to the following procedure.
1) Loosen two mounting bolts (10).
OFF position and remove the key. a One more mounting bolt (10) is at the
a Attach tags to the hoses to show their installed assembly (9).
positions to prevent any mistake when installing. 2) Move air conditioner compressor assembly
(9) and bracket (11) together in the loosening
Removal (PC300-R400-520-K-00-A)
direction of belt (12).
1. Close the fuel stop valve at the bottom of the fuel 3) Remove loosened air conditioner
tank. compressor belt (12). [*2]
2. Open the engine hood. 4) Remove four mounting bolts (13), disconnect
3. Remove fan guard (1). air conditioner compressor assembly (9)
4. Disconnect air conditioner hose clamp (2). from bracket (11), and move it to a place
5. Remove U-bolt (3) to remove air intake tube (4) where it is not an obstacle to the work. [*3]
from the KVGT. [*1]
PC360LC-10 50-73
11.Remove KCCV ventilator assembly (14). For 3) After removing the air cleaner top cover,
details, see "Removal and installation of KCCV cover the air inlet of air cleaner (17) with a
assembly". vinyl sheet etc.


1) Lift up air cleaner top cover (16) to machine, remove bolts (19), and disconnect
disconnect it from the air inlet of air cleaner receiver (20) and bracket together.
(17).
frame (A).
50-74 PC360LC-10
22.Remove undercovers (28), (29), and (30).

23.Remove drain plug (31) and drain the hydraulic
oil.
6 Hydraulic tank:
365 l

a If using tool R1 and R2, remove the hydraulic

tank strainer and stop oil with tool R1 and
R2.
21.Disconnect intake air heater E01 (26) and wiring

24.Remove the engine hood assembly, referring to

"Removal and installation of engine hood
assembly".
PC360LC-10 50-75
26.Open the side cover on the left side of the 30.Disconnect connectors E25 (40) and E26 (41)
machine and remove KDPF water drain tube according to the following procedure.
(33). [*7] • Connector E25 (40): Temperature sensor
• Connector E26 (41): Differential pressure
sensor
27.Remove covers (34), (35), and (36).
1) Slide the lever (red) of the connector to

unlock.
2) While pressing the knob on the upper portion

of the connector, pull out the connector.
29.Remove covers (38) and (39).
50-76 PC360LC-10
• Hose (54): Additional pilot filter

• Hose (55): PC-EPC source pressure (Band:
Yellow)
• Hose (56): Front pump delivery port
• Hose (57): Rear pump delivery port
31.Disconnect eight wiring harness clamps (42)

around the KDPF assembly.
36.Disconnect connector (58).

37.Disconnect six wiring harness clamps (49)
around the main pump.
39.Remove four mounting bolts (60) and
disconnect pump suction tube (61).
32.Disconnect connectors (43) to (45).

• Connector P27 (43): Front pump swash plate
sensor
• Connector P28 (44): Rear pump swash plate
sensor
• Connector V12 (45): Rear PC-EPC valve
33.Disconnect hoses (46) to (48).
• Hose (46): Front LS pressure (Band: None)
• Hose (47): Rear LS pressure (Band: Red)
• Hose (48): Drain port hose 40.Disconnect engine ground cable (62).
34.Disconnect connectors (50) and (51). 41.Disconnect hose clamps (63) to (68).
• Connector V11 (50): Front PC-EPC valve 42.Remove radiator hoses (69) to (72).
• Connector V19 (51): LS-EPC valve 43.Remove fan guard (73).
35.Disconnect hoses (52) to (57).
• Hose (52): Front pump pressure (Band:
None)
• Hose (53): Rear pump pressure (Band: Red)
PC360LC-10 50-77
44.Remove brackets (74). 49.Disconnect fan (81).
45.Disconnect aftercooler tube (76) from the KVGT. 50.Disconnect fuel return hose (82) and fuel supply
[*8] hose (83). [*10]
46.Remove two U-bolts (75) fixing aftercooler tube 51.Remove cover (84).
(76).
a Remove these bolts so that the engine
mounting bolts are removed easily.
52.Disconnect fuel filter hoses (85) and (86).
47.Disconnect wiring harnesses of terminal E (77)

and terminal R (78) from alternator (80). [*9]
53.Disconnect hose clamp (87) of lower radiator

hose (88).
50-78 PC360LC-10
54.Remove radiator hose (88).
62.Disconnect engine oil level switch connector

55.Disconnect hose clamp (89). P44 (98).
56.Remove bracket (90). 63.Disconnect wiring harness clamps (99) to (101).
57.Remove hose (91).
64.Disconnect wiring harness connector CE03

58.Disconnect hose (92). (103) from engine controller (102). [*12]
59.Disconnect engine body ground cable (93). a Thoroughly clean the surrounding area to
60.Disconnect wiring harness clamps (94) and (95). remove mud and other contamination to
61.Disconnect wiring harness of terminal B (97) prevent them from entering the connector
from starting motor (96). hole.
a The connectors are locked with hexagonal
socket head bolts (104) (4 mm).
66.Disconnect connector E24 (106) according to
the following procedure. [*13]
PC360LC-10 50-79
a Thoroughly clean the surrounding area to

remove mud and other contamination to
prevent them from entering the connector
hole.
70.Sling and remove engine and main pump

assembly (112).
a Ensure that all the wiring, piping, clamps, etc.
are disconnected before removing.
1) Slide lever (red) (107) toward you to unlock. a Tool A11 (lifting tool) is prepared. (See
2) Grab and pull out connector (106) while Special tools list)
pressing locking tab (108).
a Locking tab (108) is on the top of 4 Engine and main pump assembly:
connector (106). 1,400 kg

68.Disconnect engine oil filter (110) and bracket
together, and bind and fix them to the engine
assembly with ropes etc.
69.Remove four engine mounting bolts (111). [*14]
50-80 PC360LC-10
a Sling position of engine and main pump

assembly (112)
• Air conditioner compressor mounting
bracket (113)
4) Remove bolt (120) at the center of gravity of

main pump assembly (115).
• KDPF assembly mounting bracket (114)
5) Install eyebolt [1].

a As for eyebolt [1], do not use one installed
to main pump assembly (115) but use a
71.Remove main pump assembly (115) from the one of sufficient size which withstands
removed engine and main pump assembly the load.
according to the following procedure. 6) Sling main pump assembly (115) with wire [2]
and remove mounting bolt (121).
1) Remove drain plug (116) and drain the
damper oil. a Sling main pump assembly (115) by one
point. Install auxiliary holding rope [3] to
6 Damper case: eyebolt (122) to prevent the main pump
1.3 l assembly from turning and eyebolt [1]
from coming off.
7) Sling and remove main pump assembly
(115).
2) Remove the tube clamp and damper case oil

filler pipe (119). [*15]
3) Remove blocks (117) and (118) to sling main
pump assembly (115).
PC360LC-10 50-81

4 Main pump assembly (115):
hose.
225 kg
3 Clamp bolt:
16 to 17 Nm {1.6 to 1.7 kgm}
to 7 mm.
Installation (PC300-R400-720-K-00-A)

removal.
[*1]
3 Hose clamp: [*6]
10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}
3 U-bolt mounting nut: 4.0 ± 0.6 Nm {0.41 ± 0.15 kgm}
14.7 to 44.1 Nm {1.5 to 4.5 kgm} [*7]
[*2]
a Insert and install KDPF water drain tube (33) into
a Adjust the air conditioner compressor belt I-joint (123) of the KDPF assembly.
tension. For details, see Testing and adjusting, • Tube insertion length (A): 31.5 mm
[*3]
3 Air conditioner compressor assembly
mounting bolt:
10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}
[*4]
10.8 to 26.5 Nm {1.1 to 2.7 kgm}
[*5][*8]
[*9]
a Install the wiring harnesses to terminal E (77)
and terminal R (78) of alternator (80).
3 Terminal E (77):
a With bridge (BR) set under the clamp bolt, 2.4 to 3.0 Nm {0.24 to 0.31 kgm}
the band by dimension (b) indicated below. 3 Terminal R (78):
• Dimension (b): Min. 5 mm 2.4 to 3.0 Nm {0.24 to 0.31 kgm}

equivalent)
50-82 PC360LC-10
[*10] [*13]
a Install fuel return hose (82) and fuel supply hose Installation procedure for connector E24 (106)
(83). 1. Fit connector (106) and slide its outside portion
deep until it is locked.
3 Sleeve nut:
2. Push in lever (red) (107) deep to lock connector
54 to 93 Nm {5.5 to 9.5 kgm} (106).
[*11] [*14]
a Install the wiring harness to terminal B (97) of a The bolt length of the engine front side is shorter
starting motor (96). than that of the rear side.
3 Terminal B (97): a The engine mounting rubber size of the engine
19.6 to 25.5 Nm {2.0 to 2.6 kgm} front side is smaller than that of rear side.
[*12] 3 Mounting bolt of engine mount (front

side):
3 Hexagonal socket head bolt (4 mm) (104):
320 to 400 Nm {33 to 41 kgm}
3 ± 1 Nm {0.31 ± 0.1 kgm}
PC360LC-10 50-83
3 Mounting bolt of engine mount (rear • Bleeding air (hydraulic system)

side): Bleed air from the hydraulic circuit. For details,
785 to 980 Nm {80 to 100 kgm} see Testing and adjusting, "Bleeding air from
hydraulic system".
[*15]
3 Joint bolt of damper case oil filler pipe
(119):
127 to 167 Nm {13 to 17 kgm}
2 Main pump involute splines:

Molybdenum disulfide grease (LM-G)
2 Mating face on main pump case:
a Take care not to torque the bolts excessively
since the flywheel housing is made of aluminum.
• Refilling (damper case)
Refill hydraulic oil through the oil filler port to the
specified level.
5 Damper case:
1.3 l
3 Damper case drain plug:
58.8 to 78.4 Nm {6 to 8 kgm}
• Refilling (hydraulic tank)
Supply oil through the oil filler to the specified
level. Run the engine to circulate the oil through
the system. Then, check the oil level again.
5 Hydraulic tank:
365 l
3 Hydraulic tank drain plug:
75 ± 8 Nm {7.65 ± 0.8 kgm}
• Checking for fuel leakage (fuel system)
Check the fuel system for leakage. For details,
system".
50-84 PC360LC-10
Removal and installation of engine front seal (PC300-A350-924-K-00-A)
a Special tools
Necessity
Symbol
Q'ty
Part No. Part name
A 8 795-799-8120 Installer q 1
Removal (PC300-A350-520-K-00-A)
1. Remove the radiator assembly. For details, see

"Removal and installation of radiator assembly.
2. Remove the hydraulic oil cooler assembly. For
details, see "Removal and installation of
hydraulic oil cooler assembly". 7. Remove fan guard (7).
3. Remove the aftercooler assembly. For details,
see "Removal and installation of aftercooler
assembly."
4. Disconnect two air conditioner hose clamps (1).
8. Disconnect hose clamp (8).

10.Loosen two mounting bolts (10).
a One more mounting bolt is at the bottom of
5. Remove eight bolts (2), remove air conditioner air conditioner compressor assembly (11).
condenser (3) from the stay, and move it to a 11.Move air conditioner compressor assembly (11)
place where it is not an obstacle to the work. and bracket (12) together in the loosening
a When moving air conditioner condenser (3), direction of air conditioner belt (13).
take care not to deform air conditioner hoses
(4) and (5).
6. Remove fan (6).
PC360LC-10 50-85
12.Remove air conditioner belt (13). [*1] 14.Remove tensioner assembly (15) and bracket
13.Remove fan belt (14). (16).
15.Remove alternator belt (17).
a Set a wrench to portion (A) (width across
flats T: 12.7 mm) of tensioner assembly (15) a Set a wrench to portion (A) (width across
and turn it in the winding direction. flats T: 12.7 mm) of tensioner assembly (18),
and turn it to the opposite to the winding
k Firmly set the wrench on tensioner direction to decrease the alternator belt (17)
assembly (15) at portion (A) before tension.
spring of tensioner assembly (15) is k Firmly set the wrench on tensioner
strong. If the wrench is loosely inserted, assembly (18) at portion (A) before
the wrench may accidentally come off and applying turning force to the wrench. (The
this is extremely dangerous.) spring of tensioner assembly (18) is
strong. If the wrench is loosely inserted,
k After removing fan belt (14), slowly and the wrench may accidentally come off and
carefully restore tensioner assembly (15). this is extremely dangerous.)
k Be careful not to get your fingers caught k After removing the alternator belt (17),
between the pulley and fan belt (14) slowly and carefully restore tensioner
during work. assembly (18).

between the pulley and alternator belt (17)
during work.
50-86 PC360LC-10
16.Remove five bolts (19) and pulley (20).

3) Remove front oil seal (26).
17.Remove five bolts (21) and vibration damper
(22).
18.Remove the front oil seal according to the
following procedure. 1. Wipe off material sticking to the crankshaft
flange with clean cloth.
1) Remove dust seal (23) from front oil seal 2. Set tool A8 to front oil seal (26) from the pilot [1]
carrier assembly (24). side.
a Since pilot [1] is a plastic part inside the front
oil seal used as a guide for the crankshaft, do
not remove it from the front oil seal.
2) Remove front oil seal carrier (24) from the

front cover (25).
3. Install front oil seal (26) from inside of front oil

seal carrier (24).
4. Place pilot [1] to the crankshaft and push it and
front oil seal carrier (24) together onto the
crankshaft with hand.
5. Remove pilot [1].
PC360LC-10 50-87

200 ± 10 Nm {20.4 ± 1.02 kgm}
10.Install pulley (20).
43 ± 6 Nm {4.38 ± 0.61 kgm}
6. Apply liquid gasket to the following areas and

install front oil seal carrier (24).
• All inside wall (a) of front oil seal carrier (24)
• Threaded portion (b) of bolt (27) and contact
surface (c) of front oil seal carrier
• Threaded portion (d) of nut (28)
11.Install alternator belt (17).
2 (a), (b), (c), and (d) in figure:
Liquid gasket (LG-7) a Set a wrench to portion (A) (width across
flats T: 12.7 mm) of tensioner assembly (18)
and turn it in the winding direction.
k Firmly set the wrench on tensioner

spring of tensioner assembly (18) is
the wrench may accidentally come off and
this is extremely dangerous.)
k After installation of alternator belt (17),

restore tensioner assembly (18) slowly
with care.
7. Tighten mounting nuts (28) of front oil seal
carrier (24) in the numeric order ([1] o [5]) k Be careful not to get your fingers caught
shown in the figure. between the pulley and alternator belt (17)
3 Mounting nut: during work.
8 ± 1 Nm {0.82 ± 0.1 kgm} 12.Install tensioner assembly (15) and bracket
8. Install dust seal (23). assembly (16).
a Push in the dust seal until it reaches the front 3 Mounting bolt:
oil seal. 43 ± 6 Nm {4.38 ± 0.61 kgm}
9. Install vibration damper (22).
50-88 PC360LC-10

order to removal.
[*1]
a See Testing and adjusting, "Checking and
adjusting air compressor belt tension".
13.Install fan belt (14).

a Set a wrench to portion (A) (width across
flats T: 12.7 mm) of tensioner assembly (15)
and turn it in the winding direction.
k Firmly set the wrench on tensioner

spring of tensioner assembly (15) is
the wrench may accidentally come off and
this is extremely dangerous.)
k After installation of fan belt (14), restore

tensioner assembly (15) slowly with care.

between the pulley and fan belt (14)
during work.
PC360LC-10 50-89
Removal and installation of engine rear seal (PC300-A510-924-K-00-A)
a Special tools 1) Place blocks under the engine oil pan to float
flywheel housing (4).
Necessity
Symbol
2) Remove engine mounting brackets (5) and
Q'ty
Part No. Part name (6) from flywheel housing (4).
3) Set slings to flywheel housing (4).
4) Remove mounting bolts (7).
9 790-501-2001 Repair stand t 1 5) Sling and remove flywheel housing (4).
A
10 790T-901-6030 Adapter t 1
Removal (PC300-A510-520-K-00-A)
4 Flywheel housing:
60 kg
1. Remove the engine and main pump assembly
and separate them from each other. For details,
see "Removal and installation of engine and
main pump assembly".
2. Remove damper assembly (1). [*1]
5. Remove the engine rear oil seal according to the

1) Remove rear cover (8).
a When separating rear cover (8) and
3. Remove the flywheel assembly according to the engine oil pan gasket, take care not to
following procedure. damage the engine oil pan gasket.
1) By using blocks [7], fix the engine assembly.
a Insert a feeler gauge etc. between the
a Tools A9 (repair stand) and A10 (adapter) bottom of rear cover (8) and engine oil
are prepared. (See the special tools pan gasket and move it back and forth to
table) separate the gasket.
1) Sling flywheel assembly (3).
a When engine oil pan gasket is damaged
2) Remove mounting bolt (2).
[*3]
3) By using guide bolts [1], sling and remove
flywheel assembly (3). [*2] 1] Drain the engine oil from the engine oil
pan.
4 Flywheel assembly (3):
6 Engine oil pan:
40 kg
35 l
2] Remove engine oil pan (9).
a Replace the engine oil pan gasket.
3] Remove dust seal (10).
4. Remove the flywheel housing according to the

50-90 PC360LC-10
a Since plastic pilot [2] inside the rear oil seal

(11) is used as a guide for the crankshaft in
installation, do not remove it from the rear oil
seal.
2) Remove engine rear oil seal (11) from rear

cover (8).
4. Install engine rear oil seal (11) to rear cover (8).
1. Clean, degrease, and dry the gasket contact

surface of the rear cover and cylinder block.
2. Clean, degrease, and dry the engine rear oil seal 5. By using alignment tool [3], push engine rear oil
contact surface of the crankshaft. seal (11) into proper depth of rear cover (8).
a Alignment tool [3] (positioning tool) is
attached to the engine rear oil seal.
6. Remove alignment tool [3].
3. Apply neutral detergent to the periphery of

engine rear oil seal (11).
7. Apply liquid gasket according to the following

procedure.
1) Apply liquid gasket to bold-line portion (a) of
the underside of rear cover (8).
PC360LC-10 50-91
2 Apply a bead of liquid gasket 3 mm

in diameter to bold-line portion (a)
of underside of rear cover (8):
12.Install alignment tool [3] again and check that

engine rear oil seal (11) is pushed in to proper
depth.
a Do not remove alignment tool [3] but keep it
2) Apply liquid gasket thickly to two hatched installed.
areas (b) in the following figure. 13.Remove guide pin [4] mentioned above.
14.Tighten four oil pan mounting bolts (indicated by
2 Hatched area (b): the arrows) loosely.
Liquid gasket (LG-7) 15.Tighten the eight mounting bolts of rear cover
(8) in the order shown in the following figure.
3 Rear cover (8) mounting bolt:
12.7 ± 2.0 Nm {1.3 ± 0.2 kgm}
16.Tighten four oil pan mounting bolts (indicated
with arrows) to the specified torque.
3 Mounting bolt:
24 ± 4 Nm {2.45 ± 0.41 kgm}
17.Remove alignment tool [3].
8. Install guide pin [4] to the cylinder block.

9. While positioning with guide pin [4], install
gasket (12).
10.Place pilot [2] to the crankshaft and push it
together with rear cover (8) with the hand.
a Cut gasket (12) so that its protrusion (c) from
the engine oil pan is as follows.
Protrusion dimension (c): Max. 0.25 mm
11.Remove pilot [2].
50-92 PC360LC-10
18.Install dust seal (10) a After rotating the crankshaft by one turn,
check that the pointer of the dial gauge
[5] reads the value at the start of rotation.
19.Install flywheel housing (4).
4 Flywheel housing: • Measuring facial runout

60 kg 1) Similarly to the measurement of the radial
2 Bead line 1 - 3 mm in diameter around runout, place the probe of dial gauge [5] at a
mounting bolt hole on cylinder block: right angle to the end face of the flywheel
housing.
a When measuring, move the crankshaft to
3 Flywheel housing mounting bolt (3): either front or rear end to eliminate error
77 ± 12 Nm {7.9 ± 1.2 kgm} caused by the end play.
a Tighten the mounting bolts in the following 2) Set the pointer of dial gauge [5] to "0", rotate
order. the crankshaft by one turn, and measure the
difference of the maximum reading of the
pointer of dial gauge [5].
20.After installing the flywheel housing, measure

the radial runout and facial runout with dial
gauge [5].
a Radial runout: Max. 0.20 mm • Carry out the rest of installation in the reverse
order to removal.
a Facial runout: Max. 0.20 mm
• Facial runout: Max. 0.20 mm
[*1]
1) Install dial gauge [5] to the end face of the
crankshaft. 2 Damper assembly mounting bolt:
2) Place the probe of dial gauge [5] at a right Adhesive (LT-2)
angle to the spigot joint portion of the
flywheel housing. 2 Spline of damper:
3) Set the pointer of dial gauge [5] to "0", rotate Molybdenum disulfide anti-friction
the crankshaft by one turn, and measure the lubricant (LM-G)
difference of the maximum reading of the [*2]
pointer of dial gauge [5].
a By using guide bolts [1], sling and install flywheel
assembly (3).
PC360LC-10 50-93
1. Install dial gauge [5] to the flywheel housing.

4 Flywheel assembly (3):
2. Place the probe of dial gauge [5] at a right
40 kg angle to spigot joint portion (d) or periphery
of the flywheel.
3. Set the pointer of dial gauge [5] to "0".
4. Rotate the crankshaft by one turn and
measure the difference of the maximum
reading of the pointer of dial gauge [5].
a After rotating the crankshaft by one turn,
check that the pointer of the dial gauge
[5] reads the value at the start of rotation.
• Measuring facial runout
1. Similarly to the measurement of the radial
runout, place the probe of dial gauge [5] at a
right angle to end face (e) of the periphery of
the flywheel.
a Fix the flywheel and flywheel housing with bar
[6]. a When measuring, push the crankshaft to
the front or rear so that an error is not
caused by the end play.
2. Set the pointer of dial gauge [5] to "0".
3. Rotate the crankshaft by one turn and
measure the difference of the maximum
reading of the pointer of dial gauge [5].
a Tighten the mounting bolts in the following order.

2 Flywheel mounting bolt:
3 Flywheel mounting bolt:
137 ± 7 Nm {14.0 ± 0.7 kgm}
[*3]
a If the engine oil pan was removed, install it
1. Apply liquid gasket to portion (e) of the cylinder
block.
2 Portion (e
e ) of cylinder block:
a Measure the facial runout and radial runout of

the flywheel.
• Radial runout: max. 0.13 mm
• Facial runout: max. 0.02 mm
• Measurement of radial runout
50-94 PC360LC-10
2. Install the gasket to the bottom of the cylinder

block.
a Apply liquid gasket to neither side of the
gasket.
3. Install bed plate (14) to cylinder block (13).
a Apply liquid gasket to neither side of the bed
plate.
4. Apply liquid gasket to hatched areas (j) of the

bed plate side of gasket (15).
2 Hatched areas (j) on bed plate side of
gasket (15):
Liquid gasket (LG-7) 6. Apply liquid gasket to hatched area (k) of the
a Do not apply liquid gasket to the oil pan. mounting face of engine oil pan (9).
5. Install gasket (16) to the end flange and install 2 Hatched area (k) of mounting face of
suction tube (17). engine oil pan (9):
2 End flange: Liquid gasket (LG-7)
Liquid gasket (LG-7) 7. Install engine oil pan (9) to the cylinder block.
3 Flange mounting bolt (18):

7.8 ± 2 Nm {0.8 ± 0.2 kgm}
PC360LC-10 50-95
8. Tighten the mounting bolts in the numerical

order shown in the figure below.
3 Mounting bolt of engine oil pan (9):
24 ± 4 Nm {2.4 ± 0.4 kgm}
• Refilling with oil (engine oil pan)

Add oil through the oil filler to the specified level.
Run the engine to circulate the oil through the
system. Then, check the oil level again.
5 Engine oil pan (engine oil):

35 l
(For details, see "Table of fuel,
coolant and lubricants")
Bleed air from the fuel circuit. For details, see
circuit".
50-96 PC360LC-10
Removal and installation of fuel tank assembly (PC220-AD10-924-K-00-A)
k Park the machine on a level ground, swing

the upper structure by 90 deg., lower the
work equipment to the ground stably, and
stop the engine.
k Set the lock lever in the Lock position.

Removal (PC300-AD10-520-K-00-A)
1. Remove undercovers (1) and (2). 4. Open the battery case cover and remove grease
gun (6).
5. Remove two bolts (7) from the lower mounting
portion of handrail (4).
2. Open the right side cover and open fuel tank

drain valve (3) to drain the fuel.
6 Fuel tank (when full): 6. Remove handrail (4).

7. Remove handrail (8) and plate (9).
605 l
3. Remove mirror (5) from handrail (4).

9. Open the battery case cover and remove two
bolts (12).
PC360LC-10 50-97
14.Sling and remove fuel tank assembly (21).
4 Fuel tank assembly:

250 kg
10.Close the battery case cover and remove two

mounting bolts (13) to remove cover (14).
Installation (PC300-AD10-720-K-00-A)

removal.

system".
11.Disconnect wiring harness clamp (15) and
connector P21 (16) of the fuel level sensor.
12.Disconnect fuel tank lower hoses (17), (18), and

(19).
13.Remove six mounting bolts (20).
50-98 PC360LC-10
Removal and installation of engine hood assembly (PC220-H540-924-K-00-A)
Removal (PC300-H540-520-K-00-A)
1. Open and sling engine hood (1).
a Close engine hood (1) with slings set.[*1][*2]
2. Remove gas springs (2) and (3).

3. Remove stay (4).
a Fix disconnected gas springs (2) and (3) and
stay (4) with tapes etc. so that they do not
interfere with the engine when the engine
hood is opened and closed.
5. Lift off engine hood (1).
4 Engine hood:
90 kg
Installation (PC300-H540-720-K-00-A)

removal.
[*1]
4. Close engine hood (1) and remove four Adjustment procedure for installed engine hood
mounting bolts (5) at the rear of the engine hood.
1. Tighten engine hood (1) with four mounting bolts
(5).
a Lightly tighten the bolts to the degree that the
engine hood does not move to the right and
left, and back and forth when it is opened
and closed.
PC360LC-10 50-99
a Keep the engine hood slung after installation

to perform adjustments.
[*2]
Adjustment procedure of catcher
2. Lower engine hood (1) slowly to bring catch (6) a When installing the engine hood, adjust lock
near to pin (7) on the chassis and check the portion of catch (6) according to the following
engagement. procedure.
1. Loosen mounting bolts (9) of catch (6).
3. Adjust fore-and-aft location of engine hood (1)

so that spring box (8) of catch (6) is nearly
2. While pulling the lever of catch (6) to the level,
perpendicular.
hitch catch-hook (10) to the tooth of pin (7) on
the frame side.
4. If adjustment is necessary, loosen the four

engine hood mounting bolts and move the 3. While pulling up catch (6) to the end with the
engine hood to adjust. lever on level, make a mark of the bottom of the
a Repeat Steps 2 and 3 until the engine hood catch bracket.
is opened and closed smoothly. 4. While matching with the mark, tighten mounting
5. After adjustment is completed, tighten engine bolts (9).
hood mounting bolts (5) to the specified torque.
50-100 PC360LC-10
5. Check that catch (6) is locked smoothly.

a Repeat Steps 1 to 4 until catch (6) is locked
smoothly.
PC360LC-10 50-101
Removal and installation of KDPF assembly (PC300-A9H0-924-K-00-A)
a Special tools
Necessity
Symbol
Q'ty
Part No. Part name
Commercially Long socket

A 12 q 1
available (7/16 in)

k Check and remove any accumulated dirt and

combustibles (dead leaves, twigs, etc.) on 7. Remove covers (6), (7), and (8).
the KDPF.
Removal (PC300-A9H0-520-K-00-A)
1. Open engine hood assembly (1).

2. Remove KCCV ventilator assembly (2). For
assembly".
3. Remove step (3).
4. Remove frame (4).
5. Open the side cover on the left side of the

machine and remove KDPF water drain tube (5).
6. Remove I-joint (12) from the KDPF assembly.
[*1]
9. Remove covers (10) and (11).
10.Disconnect connectors E25 (13) and E26 (14)

50-102 PC360LC-10
• Connector E25 (13): Temperature sensor

• Connector E26 (14): Differential pressure
sensor

clamp (16) and disconnect KDPF assembly (21)
and tube (17).
1) Slide the lever (red) of the connector to a Make a matchmark on the tube and V-clamp
unlock. before removing.
7/16 in (11.1 mm)
13.Disconnect tube (17) from KVGT piping bracket
(30).
14.Remove tube (17) according to the following
procedure, if necessary.
1) By using tool A12 (long socket), remove V-
clamp (18).
a Make a matchmark on the tube and V-
clamp before removing.
a Width across flats of V-clamp fastening
2) While pressing the knob on the upper portion nut: 7/16 in (11.1 mm)
of the connector, pull out the connector. 2) Remove U-bolt (19) to remove tube (17).
a Take care that spacer (20) will not fall.
15.Disconnect the harness clip (32a).
16.Disconnect the clamp (33) of wiring harness (32)
and hose (33). [*2]
17.Remove four bolts (22) from bracket (23).
11.Disconnect eight wiring harness clamps (15)

around the KDPF assembly.
PC360LC-10 50-103
18.Sling and remove KDPF assembly (21) from 20.Remove nuts (24) and (25) and washers, and
bracket (23). then remove U-bolt (26).
a Be sure to install the sling to bracket (23). a Loosen nuts alternately to protect U-bolt
(Do not use hangers (27) of KDPF assembly thread from being galled.
(21).) 21.Sling and remove KDPF assembly (21) from
bracket (23).
a When slinging, take care that the gasket of
the tube connection will not fall. a When lifting KDPF assembly (21), install the
slings to two hangers (27).
a If the tube was not removed, move it to a
position where the tube connection does not 4 KDPF assembly (21):
interfere with the KDPF assembly before
50 kg
slinging.
clamp (28) from KDPF assembly (21), and then
4 KDPF assembly (21), bracket (23):
remove exhaust pipe (29) and gasket.
95 kg
7/16 in (11.1 mm)
19.Remove base bracket (24) according to the

following procedure, if necessary.
1) If wiring harness is connected to the base Installation (PC300-A9H0-720-K-00-A)
bracket (24), disconnect it.
1. Before installing the removed V-clamp, check it
2) Remove two bolts (25) on the side of base
for abnormality.
bracket (24).
3) Remove eight bolts (26), then sling and a V-clamp can be reused, however, replace it
remove base bracket (24). with a new one in the following conditions.
4 Base bracket (24): • Damage on T-bolt thread portion
35 kg • Crack at V groove
• Peeling at V groove
50-104 PC360LC-10
3. If base bracket (24) was removed, install it

2. Install KDPF assembly (21) to bracket (23)
1) Install base bracket (24) with eight bolts (26).
1) Sling KDPF assembly (21) to mount it on
bracket (23), and tighten washers (24) and
nuts (25) at four places for the two U-bolts 4 Base bracket (24):
(26) so lightly that the position of the 35 kg
assembly can be adjusted. 2) Install two bolts (25) on the side of base
bracket (24).
a When lifting KDPF assembly (21), install
the slings to two hangers (27).
a When nut (25) is chamfered only one side,
install it with its chamfered side
downward.
4 KDPF assembly (21):

50 kg
2) Clean exhaust pipe (29) and the flange of the
KDPF assembly with parts cleaner.
3) Install a new gasket between exhaust pipe
(29) and the flange of the KDPF assembly.
4) Install V-clamp (28), adjust the angle
between exhaust pipe (29) and the T-bolt of 4. Mount KDPF assembly (21),which is tightened
V-clamp to 45 deg., and then tighten the lightly to bracket (23), on base bracket (24).
clamp lightly with tool A12 (long socket). a Be sure to install the sling to bracket (23).
a Tighten the V-clamp to the specified (Do not use hangers (27) of KDPF assembly
torque after the installation to the (21).)
machine.
a If the tube was not removed, lower it to a
position where the tube connection does not
interfere with the KDPF assembly during
installation, and then move it to the position
for installation.
4 KDPF assembly (21), bracket (23):

95 kg
PC360LC-10 50-105
5. Tighten bracket (23) with four bolts (22).

6. Set exhaust pipe (29) at a right angle (90 ° ) to
the engine crankshaft.
a Do not set the exhaust pipe in parallel with
the axis of KDPF assembly (21). (Angle of
exhaust pipe (29) to KDPF assembly (21): 3
°)
8. Tighten tube (17) and spacer (20) with U-bolt

(19).
a Measure distance (b) between the end of
bellows of tube (17) and the top of the head
cover.
• Distance (b): 220.5 ± 1 mm
7. Position the inlet flange of KDPF assembly (21).
3 U-bolt fastening nut:
• Rotation direction: Adjust so that exhaust
14.7 to 44.1 Nm {1.5 to 4.5 kgm}
pipe (29) is perpendicular to the flange.
9. By using tool A12 (long socket), tighten V-clamp
• For-and-aft direction: Adjust dimension (a)
(18) lightly.
between bracket (23) and KDPF assembly
(21). • Width across flats of V-clamp fastening nut:
7/16 in (11.1 mm)
a Dimension (a): 45 mm
10.Fit the gasket between the inlet flange of KDPF

assembly (21) and the flange of tube (17) and
check the clearance.
a Adjust the clearance to 5 mm or less all
around.
50-106 PC360LC-10
a When adjusting the clearance, loosen four

each of nuts (24) and (25) of U-bolt (26) and
move in the turning direction to adjust finely.
a If the clearance cannot be adjusted finely in
the turning direction, loosen bracket
mounting bolts (22) and adjust by moving
bracket (23).
(16) lightly.
7/16 in (11.1 mm)
7/16 in (11.1 mm)
6.9 to 8.8 Nm {0.7 to 0.9 kgm}
7/16 in (11.1 mm)
6.9 to 8.8 Nm {0.7 to 0.9 kgm}
14.If nuts (24) and (25) of U-bolt (26) were
loosened, tighten evenly at the four places.
31.4 ± 12.7 Nm {3.2 ± 1.3 kgm}
44.1 ± 18.6 Nm {4.5 ± 1.9 kgm}
15.If mounting bolts (22) of bracket (23) were
loosened, tighten them.
16.Finger-tighten brackets (30) and (31) for KDPF
piping.
17.Install tube (17) to KDPF piping bracket (30).
a Do not make clearance on the mounting a When tightening U-bolt fastening nuts (24)
face. and (25), install a spanner head to a
interchangeable-head torque wrench to
2 Mounting bolt: tighten them.
3 Mounting bolt:
78.5 to 88.5 Nm {8.0 to 9.0 kgm}
18.Tighten brackets (30) and (31) for KDPF piping
19.Close engine hood (1) to check for interference

between exhaust pipe (29) and engine hood
PC360LC-10 50-107
hole. If necessary, loosen V-clamp (28) by using

tool A12 (long socket) to adjust the angle to T-
bolt to 45 degrees and retighten.
a Clearance between exhaust pipe (29) and
hole of engine hood (1)
Right and left of exhaust pipe (c): Min. 30
mm
Front of exhaust pipe (d): Min. 120 mm
7/16 in (11.1 mm)
6.9 to 8.8 Nm {0.7 to 0.9 kgm}

order to removal.
[*1]
a Install I-joint (12) of KDPF assembly, and then
insert and install KDPF water drain tube (5).
• Tube insertion length (e): 31.5 mm
[*2]
a Install harness clip (32a), and install hose and
wiring harness clamp (33a) so that their angle is
30 deg.
50-108 PC360LC-10
Disassembly and assembly of KDPF (PC300-A9H0-926-K-00-A)
a Special tools
Necessity
Symbol
Q'ty
Part No. Part name

12 q 1
available (7/16 in)
A
13 q 1
available (1/2 in)
k Since the temperature of KDPF or KDOC

becomes 500 °C or higher, take care not to
get burn injury. a Prepare block [1] referring to the figure below,
and use it with wooden plate to float the inlet
k Stop the engine and wait until the side flange from the ground.
temperature of piping around engine drops,
then remove KDPF.
k When cleaning, replacing or disposing KDPF

and CSF, use dust mask during the work to
prevent inhaling deposited soot, ash, mat
material or metallic powder inside KDPF.
k Install KCSF with care to the mounting

direction.
k KDPF is fragile against shock such as falling,

handle with care, and never use damaged
part.
2. Put a match mark on the assembly for correct
k Keep the record for each KDPF unit to alignment of inlet and outlet angles at
monitor the life, and never use the KDPF reassembly.
exceeded its life.
a Put a marking on the V-clamp, inlet body and
a V-clamp and band used in KDPF is made of outlet body in alignment with the KDPF filter
stainless steel, accordingly never use air tool for and mounting portion of the differential
removal and installation of nut to avoid damage pressure sensor pipe.
on the thread part. a The angle can be adjusted at the installation
a Prepare new gaskets or bands when removing of the KDPF assembly, slight misalignment of
them. marking is allowed.
• Inlet side
Disassembly (PC300-A9H0-530-K-00-A)
1. Secure the KDPF assembly at 4 places to

support its inlet body and filter assembly by
using block [1].
• Outlet side
PC360LC-10 50-109
3. Disconnect connectors of KDOC inlet 4. Remove KDOC outlet temperature sensor (2),
temperature sensor (1), KDOC outlet and KDPF outlet temperature sensor (3).
temperature sensor (2), and KDPF outlet • Width across flats of the nut for temperature
temperature sensor (3) from sensor table (13). sensor: 14 mm
a Loosen mounting nut (25), hold the metal
portion of temperature sensors (2) and (3)
with the hand, and pull them out
perpendicularly.
a Close the sensor mounting portions with
plugs [2].
Plug [2] threads: M12 x 1.25
a Connector disconnecting procedure

1) Slide the lever (white) of the connector to
unlock.
2) While pressing the knob on the upper portion

of the connector, pull out the connector.
5. Remove differential pressure sensor pipes (5)

and (6).
1) Loosen the nuts on the filter.
• Width across flats of the nut for pipe (5):
11/16 in (17.5 mm)
• Width across flats of the nut for pipe (6):
5/8 in (15.9 mm)
50-110 PC360LC-10
2) When disconnecting connectors of 6. By using tool A13 (lock socket), remove V-

differential pressure sensor pipes (5) and (6), clamps (7) and (8), and then remove inlet body
pull them out while pushing lock (L) at the (9) and outlet body (10).
fitting. • Width across flats of V-clamp (7), (8)
tightening nut: 1/2 in (12.7 mm)
a Lock (L) at the fitting of differential

pressure sensor pipe (6) is located 7. Remove gaskets (17) and (18) to get KDPF filter
behind. assembly (11).
3) Remove differential pressure sensor pipes 8. When replacing KDPF filter (16), remove sensor
(5) and (6). table (13) and hanger (15) according to the
a Since the tube is inserted inside of CSF,
pull out pipe (5) upright. 1) Remove band (12) by using tool A12 (long
socket) to remove sensor table (13).
a Close the sensor mounting portions with 2) Remove band (14) by using tool A12 (long
plugs [3] and [4]. socket) to remove hanger (15).
Plug [3] threads: M16 x 1.5 • Width across flats of band (12), (14)
Plug [4] threads: M14 x 1.5 tightening nut: 7/16 in (11.1 mm)
3) Remove the plug from KDPF filter assembly
(11), if so attached.
PC360LC-10 50-111
a Lock (L) at the fitting of differential

pressure sensor pipe (6) is located
behind.
9. When replacing differential pressure sensor (19),

remove it according to the following procedure.
1) Loosen mounting bolt (20), and remove
differential pressure sensor (19) from sensor
table (13).
2) Disconnect the fitting of differential pressure
sensor pipes (5) and (6) to remove
differential pressure sensor (19)
a When disconnecting connectors of
differential pressure sensor pipes (5) and
(6), pull them out while pushing lock (L) at
the fitting.
10.When replacing KDOC inlet temperature sensor

(1), remove it according to the following
procedure.
1) Disconnect wiring harness clamp (4) for
KDOC inlet temperature sensor (1) from
sensor table (13).
• Width across flats of clamp bolt: 10 mm
2) Remove KDOC inlet temperature sensor (1).
• Width across flats of the nut for
temperature sensor: 14 mm
a Loosen mounting nut (25), hold the metal
portion of temperature sensor (1) with the
hand, and pull it out perpendicularly.
50-112 PC360LC-10
2) Assemble inlet body (9) to KDPF filter

assembly (11) matching with the location of
fitting for differential pressure sensor pipe
according to the marking put before removal.
a Place V-clamp (7) to inlet body (9) before
installing them to KDPF filter assembly
(11).
a When assembling inlet body (9) and
KDPF filter assembly (11), take care that
gasket (17) does not come out.
3) Tighten V-clamp (7) lightly according to the
marking put before removal and the angle
Assembly (PC300-A9H0-710-K-00-A) shown below.
1. Install KDPF assembly inlet body (9), KDPF filter • Width across flats of V-clamp fastening
assembly (11) and outlet body (10) in sequence. nut: 1/2 in (12.7 mm)
• Mounting angle of V-clamp T-bolt: 35 ± 5
a The blocks used at disassembly are used at °
assembly. • Mounting angle of V-clamps (7) and (8)
a Since the V-clamp has a locknut, tighten it
lightly to a degree that it does not move any
more by using tool A13 (long socket) .
a V-clamp can be reused, however, replace it
with a new one in the following conditions.
• Damage on T-bolt thread portion
• Crack at V groove
• Peeling at V groove
1) Place new gasket (17) on end of KDPF filter

assembly (11).
PC360LC-10 50-113
4) Install new gasket (18) on end of KDPF filter

assembly (11).
2. Tighten V-clamps (7) and (8) according to the

5) Assemble outlet body (10) to KDPF filter 1) By using tool A13 (long socket), tighten the
assembly (11) matching with the location of nuts of V-clamps (7) and (8).
fitting for differential pressure sensor pipe • Width across flats of V-clamp fastening
according to the marking put before removal. nut: 1/2 in (12.7 mm)
a Place V-clamp (8) to outlet body (9) 3 V-clamp fastening nut:
before installing them to KDPF filter 20 ± 2 Nm {2.04 ± 0.2 kgm}
assembly (11). 2) Tap the entire periphery of the V-clamp with a
a When assembling outlet body (10) and rubber hammer in the following order: a o b,
KDPF filter assembly (11), take care that c o d.
gasket (18) does not come out. 3) Tighten the nuts of V-clamps (7) and (8)
6) Tighten V-clamp (8) lightly according to the again.
marking put before removal and the angle • Width across flats of V-clamp fastening
shown below. nut: 1/2 in (12.7 mm)
• Width across flats of V-clamp fastening 3 V-clamp fastening nut:
nut: 1/2 in (12.7 mm)
20 ± 2 Nm {2.04 ± 0.2 kgm}
• Mounting angle of V-clamp T-bolt: 35 ± 5
°
• Mounting angle of V-clamps (7) and (8)
50-114 PC360LC-10
3. When a new KDPF filter is installed, install 3 Band (14) fastening nut (tightening
sensor table (13) and hanger (15) according to to the specified torque):
the following procedure. 6.3 to 8.3 Nm {0.6 to 0.8 kgm}
a Once the band is tightened, bend marks are
made on it by the corners of the fixed part.
Those marks can cause looseness when the
band is reused. Accordingly, replace the
used band with a new one.
1) Fasten hanger (15) lightly with new band (14)
by using tool A12 (long socket).
a Install hanger (15) upward and adjust it
when the V-clamp is installed.
• Width across flats of band (14) fastening
nut: 7/16 in (11.1 mm)
2) By using tool A12 (long socket), tighten
sensor table (13) lightly with new band (12). 4. Install differential pressure sensor pipes (5) and
(6) according to the following procedure.
a Install sensor table (13) at a position that
permits easy installation of piping and a Remove any plugs put on the mounting holes
adjust it during installation of the piping. at the removal.
• Width across flats of band (12) fastening 1) Install differential pressure sensor pipes (5)
nut: 7/16 in (11.1 mm) and (6) so that they extend horizontally, and
then lightly tighten the nuts.
a When a new KDPF filter is installed,
adjust the position of sensor table (13), at
which differential pressure sensor pipes
(5) and (6) can be installed easily, then
fasten band (12) by using tool A12 (long
socket).
nut: 7/16 in (11.1 mm)
3 Band (12) fastening nut:
6.3 to 8.3 Nm {0.6 to 0.8 kgm}
2) Install connectors of differential pressure
a Adjust the direction of band and its sensor pipes (5) and (6) to differential
installing place according to the marking pressure sensor (19).
location put before removal and the angle a Push in fitting of connectors until locking
shown below. sound is heard.
• Mounting angle of band T-bolt: 135 ± 5 ° 3) Install differential pressure sensor pipes (5)
and (6).
a Since lock nut is applied to the band,
tighten lightly until band does not move. • Width across flats of the nut for Hi side
pipe (5): 11/16 in (17.46 mm)
a When new KDPF filter assembly (11) is
installed, put hanger (15) at the same 3 Hi side pipe (5) mounting nut:
angle with hanger (21) at inlet body, and 24.5 to 36.5 Nm {2.5 to 3.7 kgm}
adjust it upwards when installing on the • Width across flats of the nut for Lo side
machine, and then fasten band (14). pipe (6): 5/8 in (15.88 mm)
nut: 7/16 in (11.1 mm)
PC360LC-10 50-115
3 Lo side pipe (6) mounting nut: 6. Install connectors of KDOC inlet temperature
13.6 to 19 Nm {1.39 to 1.9 kgm} sensor (1), KDOC outlet temperature sensor (2),
and KDPF outlet temperature sensor (3) to
sensor table (13).
a Do not install connectors at wrong positions.
7. When replacing differential pressure sensor (19),

install it according to the following procedure.
1) Tighten mounting bolt (20) of differential
pressure sensor (19) lightly.
2) Install connectors of differential pressure
sensor pipes (5) and (6) to differential
pressure sensor (19).
a Push in fitting of connectors until locking
sound is heard.
5. Install KDOC outlet temperature sensor (2), and 3) Tighten mounting bolt (20) of differential
KDPF outlet temperature sensor (3). sensor (19) to the specified torque.
a Remove any plugs put on the mounting holes • Width across flats of mounting bolt for
at the removal. differential pressure sensor: 10 mm
a When installing the temperature sensor,
apply seizure prevention compound to thread
portion.
3 Thread portion of temperature sensor:
• Width across flats of the nut for temperature
sensor: 14 mm
3 Temperature sensor mounting nut:
24 to 36 Nm {2.5 to 3.7 kgm}
50-116 PC360LC-10
3 Differential pressure sensor

mounting bolt:
10.9 to 16.3 Nm {1.1 to 1.7 kgm}
8. When replacing KDOC inlet sensor (1), install it

1) Install KDOC inlet sensor (1) and tighten the
nut lightly.
a When installing KDOC inlet sensor (1),
apply seizure prevention compound to
thread portion.
2 Thread portion of temperature
sensor:
Seizure prevention compound
(LC-G)
• Width across flats of the nut for
temperature sensor: 14 mm
3 Temperature sensor mounting nut:
24 to 36 Nm {2.4 to 3.6 kgm}
2) Install wiring harness clamp (4) for KDOC
inlet temperature sensor (1).
a Adjust wiring harness clamp (4) to install
as the angle and length (a) shown in the
figure.
• Adjusted wiring harness length (a): 115
mm
• Wiring harness clamp mounting angle: 80
°
3) Install connector of KDOC inlet temperature
sensor (1) to sensor table (13).
PC360LC-10 50-117
Removal and installation of KCCV assembly (PC220-A180-924-K-00-A)

k After the engine is stopped, its parts are still

hot. Accordingly, wait until they have cooled
down before starting the work.
Removal (PC300-A180-520-K-00-A)

2. Disconnect wiring harness clamp (1).
3. Disconnect wiring harness connector P57 (2).
7. Remove two mounting bolts (8) and remove
KCCV ventilator assembly (9) and bracket (10)
together.

5. Disconnect following hoses (4), (5), (6), (11) and
(12). [*1]
• Hose (4): KCCV drain hose
8. Disconnect bracket (10) from KCCV ventilator
• Hose (5): KCCV inlet hose
assembly (9).
• Hose (6): KCCV outlet hose
• Hose (11): coolant inlet hose
• Hose (12): coolant outlet hose
a When disconnecting each hose, take care of
dripping oil.
a Take measures to prevent dirt, dust, etc. from
sticking to the disconnected hoses.

removal.
[*1]
1. KCCV ventilator side of KCCV drain hose (4)
Insertion depth (b): 26 mm
Between hose tip and clamp (c): 14 mm
50-118 PC360LC-10
2. KCCV ventilator side of KCCV inlet hose (5) and

KCCV outlet hose (6)
Insertion depth (d): 20 mm
Between hose tip and clamp (e): 13.5 mm
3 KCCV drain hose clamp (4):

2.8 to 3.8 Nm {0.29 to 0.39 kgm}
3 KCCV inlet hose clamp (5):
3. Tube side of coolant inlet hose (11) and coolant 3.9 to 4.9 Nm {0.4 to 0.5 kgm}
outlet hose (12)
Insertion depth (f): 30 mm 3 KCCV outlet hose clamp (6):
Between hose tip and clamp (g): 20 mm 3.9 to 4.9 Nm {0.4 to 0.5 kgm}
3 Coolant inlet hose clamp (11):
2.8 to 3.8 Nm {0.29 to 0.39 kgm}
3 Coolant outlet hose clamp (12):
2.8 to 3.8 Nm {0.29 to 0.39 kgm}
PC360LC-10 50-119
Removal and installation of air cleaner assembly (PC220-A910-924-K-00-A)

Removal (PC300-A910-520-K-00-A)

machine and disconnect connector P23 of air
cleaner clogging sensor (1).
1) Lift up air cleaner top cover (6) to disconnect

it from the air inlet of air cleaner (7).
frame (A).
2. Remove undercover (2).
5. After removing the air cleaner top cover, cover

the air inlet of air cleaner (7) with a vinyl sheet
etc.
6. Disconnect connector P55 of mass air flow and
3. Disconnect wiring harness clamps (3) and (4) of
temperature sensor (8).
the air cleaner clogging sensor.
7. Remove hose clamp (9). [*1]
8. Remove air cleaner band (10). [*2]
4. Open engine hood (5) and remove air cleaner

top cover (6) according to the following
9. Remove air cleaner (7).
procedure.
50-120 PC360LC-10
a When disconnecting air cleaner (7) from the 3 Air cleaner clogging sensor (1):
hose, do not use lubricating oil since it may 1.96 to 3.92 Nm {0.2 to 0.4 kgm}
stick to the air cleaner clogging sensor or
mass air flow and temperature sensor and 3 Joint (12):
can cause failure. 1.96 to 3.92 Nm {0.2 to 0.4 kgm}
10.After removing air cleaner (7), cover its hose

connecting port with a vinyl sheet etc. • Perform installation in the reverse order to
a If dirt enters, it can cause engine failure. removal.
11.When replacing air cleaner (7), remove air
cleaner clogging sensor (1), mass air flow and [*1]
temperature sensor (8), air inlet seal (11), and
joint (12). a When inserting air cleaner (7) into the hose, do
not use lubricating oil since it may stick to the air
cleaner clogging sensor or mass air flow and
temperature sensor and can cause failure.
3 Hose clamp (9) fastening bolt:
10.5 ± 0.5 Nm {1.1 ± 0.05 kgm}
[*2]
3 Air cleaner band (10) fastening bolt:
17.6 to 21.6 Nm {1.8 to 2.2 kgm}
• When replacing air cleaner
Install removed air cleaner clogging sensor (1),

mass air flow and temperature sensor (8), air inlet
seal (11), and joint (12) to air cleaner (7) to be
installed.
a Cover the opening of the air cleaner with vinyl till
just before installing air cleaner to prevent the
dust from entering.
a Since intake air flow/ temperature sensor (8) is a
precision part, neither air-blow inside nor spray
detergent liquid on it.
3 Screw for intake air flow/ temperature
sensor (8):
0.98 to 1.27 Nm {0.1 to 0.13 kgm}
PC360LC-10 50-121
Removal and installation of air conditioner compressor assembly (PC220-

K590-924-K-00-A)
k Turn the battery disconnect switch to the 6. Remove air conditioner compressor belt (5)
OFF position and remove the key. according to the following procedure. [*2]
1) Loosen two mounting bolts (6).
k If refrigerant gas (R134a) gets in your eyes,
you may lose your sight. And if it touches a One more mounting bolt (6) is at the
your skins, you may suffer from frostbite. bottom of air conditioner compressor
Accordingly, put on the protective assembly (7).
eyeglasses, gloves and working suits with 2) Move air conditioner compressor assembly
long sleeves while you are collecting or (7) and bracket (8) together in the loosening
filling the refrigerant (R134a). direction of belt (5).
3) Remove loosened air conditioner
a Never release the refrigerant (R134a) to the compressor belt (5).
atmosphere.
a Ask a qualified person for collecting, adding, and
filling operations of the refrigerant (R134a).
Removal (PC300-K590-520-K-00-A)
1. Collect the refrigerant (R134a) from the air

conditioner circuit. [*1]
a Refrigerant to be collected:
750 ± 50 g
2. Open the engine hood and remove fan guard
(1).
7. Disconnect two air conditioner hoses (9) and

4. Disconnect hose clamp (3). (10). [*3]
a Plug the hose to prevent any dirt, dust and
water from entering.
a Take care not to damage or lose the O-rings.
8. Disconnect air conditioner ground cable (11).
9. Remove four mounting bolts (12), and then
remove air conditioner compressor assembly (7)
from bracket (8). [*4]

50-122 PC360LC-10
3 Hose clamp (M6 bolt):

8 to 12 Nm {0.8 to 1.2 kgm}
Installation (PC300-K590-720-K-00-A)

removal.
[*1] [*4]
• Filling air conditioner circuit with refrigerant 3 Air conditioner compressor assembly
(R134a) mounting bolt:
Fill the air conditioner circuit with refrigerant 24.5 to 29.4 Nm {2.5 to 3.0 kgm}
(R134a).
a Filling quantity:
750 ± 50 g
• Refilling of air compressor oil
For details, see Others, "Filling compressor oil".
[*2]
a See Testing and adjusting, "Checking and
adjusting air compressor belt tension".
[*3]
a When installing the air conditioner hoses and
tubes, take care to prevent any dirt, dust or
water from enterning.
tubes, check that O-rings are fitted to their joints.
a Do not reuse an O-ring since it is deformed and
deteriorated once it is used.
a When removing O-rings, use a soft tool so that
the piping will not be damaged.
a Check that there is no defect or deterioration on
the O-ring.
a Apply compressor oil (Denso: ND-OIL8) for
R134a refrigerant to O-rings.
PC360LC-10 50-123
Removal and installation of air conditioner condenser assembly (PC220-K580-

924-K-00-A)
k Turn the battery disconnect switch to the a In this removal operation, take care so as not
OFF position and remove the key. to damage the core part.

you may lose your sight. And if it touches
your skins, you may suffer from frostbite.
Accordingly, put on the protective
eyeglasses, gloves and working suits with
long sleeves while you are collecting or
filling the refrigerant (R134a).
a Never release the refrigerant (R134a) to the

atmosphere.
Removal (PC300-K580-520-K-00-A)
1. Collect the refrigerant (R134a) from the air • Perform installation in the reverse order to
conditioner circuit. [*1] removal.
a Refrigerant to be collected:
[*1]
750 ± 50 g
2. Open the engine hood and side cover on the • Filling air conditioner circuit with refrigerant
right side of the machine and remove cover (1) (R134a)
and frame (2). Fill the air conditioner circuit with refrigerant
(R134a).
a Filling quantity:
750 ± 50 g
[*2]
3. Disconnect hoses (4) and (5) from air a Do not reuse an O-ring since it is deformed and
conditioner condenser assembly (3). [*2] deteriorated once it is used.
a Plug the hose to prevent any dirt, dust and a When removing O-rings, use a soft tool so that
water from entering. the piping will not be damaged.
a Take care not to damage or lose the O-rings. a Check that there is no defect or deterioration on
4. Remove eight mounting bolts (6) and remove air the O-ring.
conditioner condenser assembly (3). [*3]
5. Remove eight mounting bolts (7), and then
remove bracket (8) from air conditioner
condenser assembly (3).
50-124 PC360LC-10

8 to 12 Nm {0.8 to 1.2 kgm}
[*3]
a Mount the air conditioner condenser assembly
by inserting cushions in place.
2 Threaded portion of air conditioner
condenser assembly mounting bolt:
Adhesive (LT-2)
3 Air conditioner condenser assembly
mounting bolt:
10 to 15 Nm {1.2 to 1.5 kgm}
PC360LC-10 50-125
Power train system
Power train system (ALL-C100-001-K-50-A)
Removal and installation of travel motor and final drive assembly (PC220-DF10-
924-K-00-A)
4 Travel motor and final drive assembly:

k Park the machine on a level place, lower the 600 kg
stop the engine.

adjusting, "Releasing remaining pressure
from hydraulic circuit".
Removal (PC300_10-DF10-520-K-00-A)
1. Remove the sprocket referring to the section

"Removal and installation of sprocket".
2. Remove cover (1). Installation (PC300-DF10-720-K-00-A)

removal.
[*1]
3 Mounting bolt of travel motor and final
drive assembly:
549 to 666 Nm {56 to 68 kgm}
• Refilling of oil
• Bleeding air
3. Disconnect drain hose (2), travel speed selector Bleed air from the travel motor circuit. For details,
hose (3), and motor hoses (4) and (5). see Testing and adjusting, "Bleeding air from
hydraulic system".
4. Sling travel motor and final drive assembly (6).

5. Remove the 21 mounting bolts, then sling and
remove travel motor and final drive assembly (6).
[*1]
a Take care that the hose mounting block is not
damaged.
50-126 PC360LC-10
Power train system
Disassembly and assembly of final drive (PC300_10-DF10-926-K-00-A)
a Special tools
Necessity
Symbol
Q'ty
Part No. Part name
796-627-1610 Wrench assembly t 1

796-627-1620 • Wrench 1
1
796-427-1140 • Pin 3
01314-20612 • Screw 3
2 796T-627-1710 Installer t 1
796T-627-1720 Push tool t 1
790-101-2510 Block t 1 2) Disassemble No. 1 planetary carrier
F
791-830-1320 Rod t 2 according to the following procedure.
01580-11613 Nut t 2 1] Drive pin (4) into shaft (5) to remove shaft
3
790-101-2570 Washer t 2 (5) from No. 1 planetary carrier (6).
01643-31645 Washer t 2
790-105-2100 Jack assembly t 1 a After removing shaft (5), remove pin
Pump (4) from shaft (5).
790-101-1102 t 1
2] Remove thrust washer (7), No. 1
4 790-331-1110 Wrench t 1
planetary gear (8), needle bearing (9),
Disassembly (PC300-DF10-530-K-00-A) and thrust washer (10).
1. Oil draining
Remove the drain plug to drain the oil from the
final drive case.
6 Final drive case:

9l
2. Remove the 22 mounting bolts. By using
eyebolts [1], sling and remove cover (1).
4 Cover:
30 kg
a If ring gear (12) is slung together with the
cover, gently tap the ring gear off the cover 5. No. 1 sun gear shaft
by using a plastic hammer. Remove No. 1 sun gear shaft (11).
6. No. 2 sun gear
Remove No. 2 sun gear (14).
7. Remove thrust washer (13).
3. Washer
Remove washer (2).
4. No. 1 planetary carrier
8. Thrust washer
1) Remove No. 1 planetary carrier assembly Remove thrust washer (15).
(3).
PC360LC-10 50-127
Power train system
2] Remove thrust washer (20), No. 2

planetary gear (21), needle bearing (22),
and thrust washer (23).
9. Ring gear
Remove ring gear (12).
4 Ring gear:
65 kg 11.Ring nut
1) Remove lock plate (24).
10.No. 2 planetary carrier assembly

1) Remove No. 2 planetary carrier assembly 2) Use tool F1 to remove ring nut (25).
(16).
12.Hub assembly
2) Disassemble the No. 2 planetary carrier 1) Using eyebolts [2], sling and remove hub
according to the following procedure. assembly (26) from the travel motor.
1] Drive pin (17) into shaft (18) to remove
shaft (18) from No. 2 planetary carrier
(19).
a After removing shaft (18), remove pin
(17) from shaft (18).
50-128 PC360LC-10
Power train system
4 Hub assembly:
110 kg
14.Remove floating seal (33) from travel motor (31).
2) Remove bearing (27).
15.By using puller [3] and push tool [4], remove

bearing (34).
a Bearing may come off without using the
3) Remove bearing outer races (29) and (30) puller.
from hub (28).
13.Remove floating seal (32). Assembly (PC300_10-DF10-710-K-00-A)
a Clean the parts completely and inspect them for

any foreign material or damage. Apply power
train oil (TO30) to the sliding surface before
assembly.
1. Hub assembly
1) By using the push tool, press fit bearing outer
races (29) and (30) into hub (28).
PC360LC-10 50-129
Power train system
2) By using tool F2, install floating seal (32) to

2. Install bearing (34) to travel motor (31).
hub assembly (26).
a Heat the inner race of bearing (34) with a
a Install the floating seal after degreasing
heater to 50 to 70 °C .
and drying the O-ring and O-ring
contacting surface completely. a After bearing (34) is installed and cooled, hit
it with a rod to check by sound that it is
a When installing the floating seal, use tool
inserted to the end.
F2 and make sure to press the O-ring.
3. By using tool F2, install floating seal (33) to
a After installing the floating seal, measure travel motor (31).
protrusion Ba-Bd of the floating seal from
a Install the floating seal after degreasing and
the housing at the measuring point shown
drying the O-ring and O-ring contacting
below.
surface completely.
a Check that the difference between
a When installing the floating seal, use tool F2
maximum value B-max and minimum
and make sure to press the O-ring.
value B-min of Ba-Bd is 1 mm or less.
• B-max – B-min < 1 mm a After installing the floating seal, measure
protrusion Ba-Bd of the floating seal from the
a After installing the floating seal, apply a housing at the measuring point shown below.
thin coat of power train oil on the sliding
surfaces. a Check that the difference between maximum
value B-max and minimum value B-min of
2 Sliding surface: Ba-Bd is 1 mm or less.
Power train oil (TO30) • B-max – B-min < 1 mm
a After installing the floating seal, apply a thin
coat of power train oil on the sliding surfaces.
2 Sliding surface:
Power train oil (TO30)
50-130 PC360LC-10
Power train system
3] While pressing the bearing inner race,

rotate the hub in both directions at least
five times.
4] Stop pressing.
5] Press the bearing again.
a Pressing force:
12.7 to 16.7 kN {1.3 to 1.7 ton}
6] Rotate the hub two to three times.
4. Using eyebolts [2], place hub assembly (26) on

the travel motor.
a Keep the metallic faces of the floating seals
in contact with each other, free from dirt.
4 Hub assembly:
110 kg
7] Measure dimension (a) under the

condition described in Step 6].
a After measuring dimension (a),
remove tool F3.
5. By using the push tool, hit bearing (27) lightly to

install.
8] Measure the thickness of ring nut (25)

and name it (b) dimension.
9] Subtract (b) from (a) and name it (c).
10]Using tool F1, tighten ring nut (25) until
dimension (d) is as follows.
(d) dimension: c (+0.06/-0.04) mm
6. Ring nut
1) Install the ring nut according to the following
procedure.
1] Rotate the hub two to three times.
2] Use tool F3 and push tool [5] to press the
inner race of bearing (27).
a Pressing force:
29.4 to 38.2 kN {3.0 to 3.9 ton}
PC360LC-10 50-131
Power train system
1) Assemble the No. 2 planetary carrier

a Replace thrust washers (20) and (23) as
well as pin (17) with new ones.
a There is trace of punching on the end
face of carrier side hole (e) which was
caused when the pin was inserted and
locked. Before installing the pin, remove
the protrusion in the pin hole as a result of
punching.
1] Install needle bearing (22) to No. 2
planetary gear (21). Fit upper and lower
2) Measure the tangential force of the hub thrust washers (20) and (23) and set the
against the motor case in the rotation gear assembly on No. 2 planetary carrier
direction using the push scale [6]. (19).
a Tangential force: 2] Align pin holes on shaft (18) and the
Max. 627 N {64 kg} carrier, and install shaft (18) by tapping it
lightly by using a plastic hammer.
a The tangential force denotes the
maximum force at start of the rotation. a Install the shaft, while rotating No. 2
planetary gear (21) with care not to
damage the thrust washers.
3) Install lock plate (24).

a Install the lock plate so that the splines
(part A) of the motor and the lock plate 3] Insert pin (17).
are in full contact. a When inserting the pin, take care that
2 Mounting bolt threaded section: the three claws (parts f) on the
periphery of the pin will not be placed
Adhesive (LT-2)
on thin-wall parts (g) of the No. 2
a Do not apply the adhesive (LT-2) to the planetary carrier. The thin-wall part
threads of the nut. may be on the opposite side
depending on carriers. Check each
carrier and avoid setting any claw of
the pin to the thin-wall part. If there is
a groove, avoid the groove.
a After assembling No. 2 planetary
carrier, check that No. 2 planetary
gear (21) rotates smoothly.
7. No. 2 planetary carrier assembly
50-132 PC360LC-10
Power train system
a After inserting the pin, punch the

portion (B) of the pin on the carrier.
9. No. 2 sun gear

Install No. 2 sun gear (14).
10.No. 1 sun gear shaft
Install No. 1 sun gear shaft (11).
11.Thrust washer
Install thrust washer (13).
2) Install No. 2 planetary carrier assembly (16).

a Align the four gear shaft ends of No. 2
planetary carrier assembly (16) with the
four dimples on the motor case end 12.Ring gear
surface to install. 1) Install the O-ring to the hub.
2) Install ring gear (12) to the hub.
4 Ring gear:
65 kg
a Degrease the mating faces of the ring
gear and hub. Do not apply liquid gasket
on the mating faces.
a Align the bolt holes of the ring gear with
those of the hub.
8. Thrust washer
Install thrust washer (15).
13.No. 1 planetary carrier assembly
PC360LC-10 50-133
Power train system
1) Assemble the No. 1 planetary carrier a After inserting the pin, punch the
according to the following procedure. portion (C) of the pin on the carrier at
two locations.
a Replace thrust washers (7) and (10) as
well as pin (4) with new ones. (Pin (4):
See Step 3])
a There is trace of punching on the end
face of carrier side hole (h) which was
locked. Before installing the pin, remove
the protrusion in the pin hole as a result of
punching.
1] Install needle bearing (9) to No. 1
planetary gear (8). Fit upper and lower
thrust washers (7) and (10) and set the
gear assembly on No. 1 planetary carrier
(6).
2) Install No. 1 planetary carrier assembly (3).

14.Washer
2] Align pin holes on shaft (5) and the No. 1 Install washer (2).
planetary carrier, install shaft (5) by
tapping it lightly by using a plastic a After installing washer (2), measure
hammer. dimension (i) from the upper end face of No.
1 planetary gear (8) to that of ring gear (12)
a Install the shaft, while rotating No. 1 to check for the correct assembly condition.
planetary gear (8) with care not to
3] Insert pin (4).
a When inserting the pin, take care that
the three claws (parts f) on the
periphery of the pin will not be placed
on thin-wall parts (g) of the No. 1
planetary carrier. The thin-wall part
may be on the opposite side
depending on carriers. Check each
carrier and avoid setting any claw of
the pin to the thin-wall part. If there is
a groove, avoid the groove.
a After assembling the carrier, check
that No. 1 planetary gear (8) rotates
smoothly.
50-134 PC360LC-10
Power train system
a If the upper end of planetary gear (8) is 3 Mounting bolt

projected from ring gear (12), check again, 1st time: 98 Nm {10 kgm}
since the parts cannot be assembled
2nd time: 100 to 110 ° (rotating
correctly.
angle)
16.Refilling of oil
Tighten the drain plug and supply power train oil
(TO30) from the oil filler port.
5 Final drive case:

9l
a Do a final check of the oil level at the
determined position after installing the final
drive assembly to the chassis.
15.Cover
1) Using eyebolts [1], install cover (1).
4 Cover:
30 kg
2 Mating faces of cover and ring
gear:
2) By using tool F4, tighten the 22 mounting

bolts.
PC360LC-10 50-135
Power train system
Removal and installation of swing motor and swing machinery

assembly (PC300-J120-924-K-00-A)
hydraulic circuit. Refer to the “Releasing
remaining pressure from hydraulic circuit”
section in the Testing and adjusting chapter
of this manual.
k Lower the work equipment completely to the

ground, stop the engine, and loosen the cap
of the hydraulic tank to release the pressure
in the hydraulic tank.
k Set the work equipment lock lever in the

LOCK position.
4. Tighten forcing screws into portions (a) shown
k Turn the battery disconnect switch to the below to disconnect the swing motor and swing
OFF position and remove the key. machinery assembly.
a Note the connector numbers and installed

positions before disconnecting wiring and hoses.
a Fit a plug or flange in the place where a
hydraulic hose is disconnected from to prevent
oil from flowing out.
Removal (PC300-J120-520-K-00-A)
1. Remove attachment hoses (1) and (2).
5. Sling and remove swing motor and swing

machinery assembly (10).
a Sling the swing motor and swing machinery
assembly gradually so that the hoses will not
be damaged.
a Take good care, when lifting the assembly,
until the spigot joint portion is separated.
2. Disconnect six swing motor hoses (3) to (8). 4 Swing motor and swing machinery
• Hose (3): between swing motor and control assembly:
valve (port MA) 500 kg
• Hose (4): between swing motor and control
valve (port MB)
• Hose (5): suction hose (port S)
• Hose (6): drain hose (port T)
• Hose (7): pilot hose for releasing swing brake
(port B)
• Hose (8): swing motor solenoid hose (port
PU)
3. Remove 12 mounting bolts (9). [*1]
50-136 PC360LC-10
Power train system
Installation (PC300-J120-720-K-00-A)

removal.
[*1]
3 Mounting bolt:
824 to 1,030 Nm {84 to 105 kgm}
• Refilling with oil (hydraulic tank)
Add hydraulic oil through the oil filler port to the
oil through the piping. Then, check the oil level
again.
• Bleeding air
Bleed air from the hydraulic circuit. For details,
see Testing and adjusting, "Bleeding air from
hydraulic system".
PC360LC-10 50-137
Power train system
Disassembly and assembly of swing machinery (PC300-J120-926-K-00-A)
a Special tools
New/redesign
Necessity
Symbol
Sketch
Q'ty
Part No. Part name
796T-626-
1 Push tool q 1 Q
1110
790-201- t 1
3 Push tool
2480
790-101-
Push tool kit q 1
5401
790-101- 4. No. 1 carrier assembly
E • Plate 1 1) Remove No. 1 carrier assembly (3).
5521
4
790-101- • Grip 1
5421
01010-
• Bolt 1
51240
793T-815-
5 Push tool t 1 Q
1110
Disassembly (PC300-J120-530-K-00-A)
1. Oil draining
Loosen the drain plug to drain the oil from the
swing machinery case.
6 Swing machinery case:

16.5 l 2) Disassemble No. 1 carrier assembly
2. Swing motor assembly according to the following procedure.
1) Set the swing motor and swing machinery Remove snap ring (4), then remove shaft (5),
assembly on block [1]. gear (6), bearing (7), thrust washer (8), and
2) Remove the ten mounting bolts and remove plate (9).
swing motor assembly (1).
5. Ring gear
3. No. 1 sun gear Remove the mounting bolts to remove ring gear
Remove No. 1 sun gear (2). (10).
50-138 PC360LC-10
Power train system
6. No. 2 sun gear

8. Shaft assembly
Remove No. 2 sun gear (11).
1) Remove 12 mounting bolts (23).
2) Set the shaft and case assembly to a press.
By using push tool [2], remove shaft
assembly (24) from case assembly (25).
7. No. 2 carrier assembly

1) Remove mounting bolts (12) to remove No. 2
carrier assembly (13).
3) Disassemble the shaft assembly according

1] By using push tool [3], remove cover
assembly (26) and bearing (27) from
shaft (28).
2] Remove oil seal (29) from cover (30).
2) Disassemble No. 2 carrier assembly

1] Push in pin (14) and drive out shaft (15)
from carrier (16).
a After removing the shaft, remove pin
(14).
2] Remove thrust washer (17), gear (18),
bearing (19), and thrust washer (20). 9. Bearing
3] Remove plate (21). By using push tool, remove bearing (31) from
case (32).
PC360LC-10 50-139
Power train system
a Take care that the liquid gasket (LG-6)

does not stick to the oil seal lip and shaft
at the time of press fitting.
Assembly (PC300-J120-710-K-00-A)
a Clean each part and check them for dirt or

damage. Apply their sliding surfaces with engine
2) Install cover assembly (26) to case (32) and
oil before installing.
tighten mounting bolts (23).
1. Bearing
By using push tools E3 and [4], press fit bearing a Match the oil path of cover assembly (26)
(27) to case (32). with drilled hole (A) of case (32).
a Use a new bearing. 2 Mounting surface of cover

a Press fitting force (reference):
0 to 26.4 kN {0 to 2,690 kg} a Take care that liquid gasket will not stick
to drilled hole (A).
3 Mounting bolt:
59 to 74 Nm {6.0 to 7.5 kgm}
2 Oil seal lip:
Grease (G2-LI)
2. Cover assembly
1) By using push tool E4, press fit oil seal (29)
to cover (30).
a Use a new oil seal.
a When not using push tool E4, use a push
tool with which you can push the rim of 3. Case assembly
the oil seal evenly. 1) Turn over case assembly (25) and set it to
a Check that oil seal (29) is not leaned. shaft (28).
2 Outer periphery of oil seal: a Take extreme care not to damage the oil
seal.
2) By using push tools E5, [5] and guide [7],
press fit the bearing inner race.
a By using push tools E5 and [5], hit the
bearing inner race with a hammer to
prevent the shaft from falling, and then
set the bearing inner race to the press to
press fit.
50-140 PC360LC-10
Power train system
a Press fit force (reference value): a There is trace of punching on the end
39 to 110 kN {3,980 to 11,260 kg} face of carrier side hole (h) which was
a Use guide [7] to prevent case assembly locked. Before installing the pin, remove
(25) from leaning. the protrusion in the pin hole as a result of
a Correct leaning of case assembly (25) by punching.
hitting its flange lightly and frequently. In 1] Install plate (21) to carrier (16).
particular, correct so that oil seal contact 2] Install bearing (19) to gear (18). Fit upper
face (B) of the shaft is set to the center of and lower thrust washers (17) and (20)
oil seal (29). and set the gear assembly to carrier (16).
3) By using push tools E1, [6], and [8], press fit 3] Align the pin holes on the shaft and the
bearing (31). carrier, and install shaft (15) by tapping it
by using a plastic hammer.
a Use a new bearing.
a Install the shaft, while rotating the
a Press both inner race and outer race of
planetary gear with care not to
the bearing simultaneously when press-
fitting. Do not press the inner race only
4] Insert pin (14).
when press-fitting.
a When inserting the pin, take care that
a After press-fitting the bearing, ensure that
the three claws
the case rotates smoothly.
((part a) on the periphery of the pin
a Press fit force (reference value): will not be placed on thin-wall part
Inner side: 15.3 to 43.2 kN {1,560 to (part b) of the carrier.
4,410 kg} The thin wall part may be on the
Outer side: 0 to 16.2 kN {0 to 1,650 kg} opposite side depending on carriers,
however. Check each carrier and
avoid setting any claw of the pin to the
thin wall part.
5] After inserting the pin, punch two places
(h) around the pin of the carrier.
6] Ensure that all the gears rotate smoothly.
4. No. 2 carrier assembly

1) Assemble No. 2 carrier assembly as follows.
PC360LC-10 50-141
Power train system
5. No. 2 carrier assembly 7. Ring gear

Set No. 2 carrier assembly (13) and tighten Install O-ring to case (29). By using eyebolts,
mounting bolt (12). install ring gear (10).
2 Mounting bolt threaded section: a Degrease the mating faces of ring gear (10)
Adhesive (LT-2) and case (29).
3 Mounting bolt:
343 to 427 Nm {34 to 43.5 kgm}
a When installing the ring gear, match its

match mark (part d) with convex part (part c)
of the case flange as shown in the following
6. No. 2 sun gear
figure.
Install No. 2 sun gear (11).
3 Mounting bolt:
245 to 309 Nm {25 to 31.5 kgm}
a Install with press fitting plate (p) down.
50-142 PC360LC-10
Power train system
8. No. 1 carrier assembly 9. No. 1 sun gear assembly

1) Assemble No. 1 carrier assembly according Install No. 1 sun gear (2).
1] Press fit shaft (5) to the carrier in the
direction of the arrow until the snap ring
groove is seen.
2] After installing snap ring (4), push it back
from the opposite side until snap ring (4)
contacts tightly with face (P) of the carrier.
a At this time, take care not to push
back the snap ring excessively.
a Install with press fitting plate (p) down.
3] Install plate (9).

4] Install thrust washer (8), bearing (7), gear
(6), and snap ring (4).
10.Swing motor assembly

1) Set swing machinery assembly (33) on block
[1].
2) Install swing motor assembly (1).
2) Install No. 1 carrier assembly (3).
PC360LC-10 50-143
Power train system
a Install the swing motor assembly so that

ring gear (10) and swing motor assembly
(1) will be set as shown below.
2 Swing motor mounting face:

3 Mounting bolt:
98 to 123 Nm {10 to 12.5 kgm}
11.Refilling of oil
Tighten the drain plug and supply oil through the
oil filler port to the specified level.
4 Swing machinery case:

16.5 l
50-144 PC360LC-10
Power train system
Removal and installation of swing circle assembly (PC220-J110-924-K-00-A)
Removal (PC300-J110-520-K-00-A)
1. Remove the revolving frame assembly. For

details, see "Removal and installation of
revolving frame assembly".
2. Set slings to swing circle assembly (1) at three
points and remove the mounting bolts to remove
the assembly. [*1]
4 Swing circle assembly:

450 kg
Installation (PC300-J110-720-K-00-A)

removal.
[*1]
2 Swing circle mounting bolt threaded
portion:
Adhesive (LT-2)
3 Swing circle mounting bolt:
1,180 to 1,470 Nm {120 to 150 kgm}
a Install the swing circle to the track frame, while
setting the inner race soft zone mark S on the
right side of the machine as shown in the figure.
2 Amount of grease filled in grease bath:
Grease (G2-LI) 33 l
PC360LC-10 50-145
Separation and connection of track shoe assembly (PC300-DTL0-924-K-00-A)
a Special tools 4. Remove track shoes (5) on the right and left
sides of master pin (2) of track (3). [*2]
Necessity
Symbol
a Loosen the four bolts by one to two turns
Q'ty
Part No. Part name
respectively and check that they rotates
lightly, and then pull them out.
1 791-630-3000 Remover and installer t 1 a If a bolt does not turn smoothly and it is
Cylinder (980 kN {100 unscrewed forcibly, the threads of itself and
N 2 790-101-1300 ton}) t 1
the link may be damaged.
3 790-101-1102 Hydraulic pump t 1
Separation (PC300-DTL0-520-K-00-A)
1. Turn the upper structure by 90 °.

2. Loosen lubricator (1) to decrease the track shoe
tension. [*1]
k Since the internal pressure of the

adjustment cylinder is very high, do not
loosen the lubricator more than one turn.
If the grease does not come out
sufficiently, start the engine and move the
machine backward and forward.
5. Using tool N, remove master pin (2). [*3]
a Press out master pin (2) with guide pin [1].
3. Position master pin (2).

1) Lift tracks (3) by stretching the work
equipment against ground. 6. Move guide pin [1] and place block [2] under
2) Move master pin (2) to a position above the track shoe (3) to support in front of the idler.
idler where it can be removed easily. 7. Pull out guide pin [1] and remove block [2] so
3) Relieve the extended work equipment, and that track shoe (3) can be separated.
lower the machine.
50-146 PC360LC-10
8. Move the machine slowly in reverse to separate

the track shoe (3). [*4]
3. Drive guide pin [1] into link (6).
Installation (PC300-DTL0-720-K-00-A)
1. While tensing wire [3] with a forklift truck, work

equipment, etc., move the machine forward
slowly to wind track shoe (3).
• Perform connection in the reverse order to

separation.
[*1]
a See Testing and adjusting, “Testing and
adjusting track shoe tension”.
[*2]
2. By using bar [4], hammer [5], etc., wind track
shoe (3) and match the pin holes of link (6). • Installation of track shoe (5)
1. Remove mud, dirt, and rust from the mating
a Place block [2] etc. under track shoe (3) in faces of shoe (5) and link and the seating faces
front of the idler to support the track shoe. of bolt (7) and nut.
2. Install shoe (5).
3 Mounting bolts (7) (4 pieces):
1) Tighten to 393 ± 39 Nm {40 ± 4 kgm}.
a Finger-tighten the four bolts until the
mating faces of the link are fitted.
a If the bolts are tightened forcibly before
the link mating faces are fitted, the
threads of bolts and link may be
damaged.
2) Retighten by 120 ± 10 °
PC360LC-10 50-147
a Press fit master pin (2) to push guide pin [1] out.
a Using tool N, press fit master pin (2), so that the
protrusion amount (a) of the master pin is the
dimension designated below.
Protrusion of master pin
a: 4.2 ± 2 mm
[*3]
a Apply grease to master pin (2). (in the area
where bushing (4) and master pin (2) come
contact: shown hatched)
2 Between bushing and master pin
(hatched area):
Grease NIGTIGHT LYK-2 from
Nippon grease Co., Ltd.: part No.
44392708
a Apply grease to the contact surfaces (B) of the

bushing end and dust seal.
2 Contact surface (B portion) between
bushing and dust seal:
Grease NIGTIGHT LYK-2 from
Nippon grease Co., Ltd.: part No.
44392708
50-148 PC360LC-10
Removal and installation of sprocket (PC220-DT60-924-K-00-A)
Removal (PC300-DT60-520-K-00-A)
1. Separate track shoe assembly. For details, see

"Separation and connection of track shoe
assembly".
2. Swing the work equipment 90 ° , then push up
the chassis with the work equipment and place
block [1] between the track frame and the track.
3. Remove the mounting bolt, then sling and

remove sprocket (1).
4 Sprocket:
75 kg
Installation (PC300-DT60-720-K-00-A)

removal.
2 Threads of sprocket mounting bolt:
Adhesive (LT-2)
3 Sprocket mounting bolt:
640 to 785 Nm {65 to 80 kgm}
PC360LC-10 50-149
Removal and installation of idler and idler cushion assembly (PC220-DTA0-924-K-00-

A)
4 Idler cushion assembly:

Removal (PC300-DTA0-520-K-00-A) 300 kg
1. Separate track shoe assembly. For details, see
"Separation and connection of track shoe
assembly".
2. Set wire [1] to idler and idler cushion assembly
(1) and move it forward with bar [2] to a position
where you can sling it easily.
Installation (PC300-DTA0-720-K-00-A)

removal.
3. While balancing idler and idler cushion

assembly (1) with wire [1] and chain block [3],
sling and remove them from track frame (2).
4 Idler and idler cushion assembly:

470 kg
4. Disconnect idler cushion assembly (4) from idler

assembly (3).
4 Idler assembly:
170 kg
50-150 PC360LC-10
Disassembly and assembly of idler (PC290-DT90-926-K-00-A)
a Special tools
Necessity
Symbol
Q'ty
Part No. Part Name
J 796-570-1020 Installer t 1
5. Remove dowel pin (8), and then remove support

(7) from shaft (5).
6. Remove bushings (9) and (10) from idler (4).
Assembly (PC290-DT90-710-K-00-A)
1. Press fit bushings (9) and (10) to idler (4).
Disassembly (PC290-DT90-530-K-00-A)
1. Remove dowel pin (1) to remove support (2).

2. Remove floating seals (3) from support (2) and
idler (4).
3. Remove idler (4) from the assembly of shaft (5)
and support (7).
a Since 230 ± 10 cc of oil is filled in, drain it at
this timing, or underlay some cloth against
any careless smearing.
4. Remove floating seals (6) on the other side from
idler (4) and the assembly of shaft (5) and 2. Install shaft (5) with O-ring (12) to support (2),
support (7). and insert dowel pin (1).
PC360LC-10 50-151
a Be sure to assemble shaft (5) with the UP

marking facing upward.
4. Install the assembly of shaft (5) and support (2)

to idler (4).
5. Turn it over, and supply oil between shaft (5) and

3. Using tool J, install floating seal (3) to idler (4) idler (4).
and the assembly of shaft (5) and support (2).
5 Amount of oil to be sealed (EO-30DH):
a Completely clean, degrease, and dry the
230 ± 10 cc
contact surfaces (hatched area shown in the
figure) of the floating seal and the O-ring.
a Apply oil to the sliding surface of the floating
seal, and take care not to have any dirt stuck
on it.
a After inserting the floating seal, check that
the inclination is less than 1 mm and
protrusion (a) is within the range of 5 to 7
mm.
50-152 PC360LC-10
3 Plug (13): 130 to 180 Nm {13 to 18

kgm}
6. Using tool J, install floating seal (6) to idler (4)

and support (7).
figure) of the floating seal and the O-ring.
on it.
a After inserting the floating seals, check that
mm.
a When mounting the idler assembly on the

machine, make sure that plug (13) faces right
side of the machine.
7. Install shaft (5) with O-ring (11) to support (7),

and insert dowel pin (8).
a See figure of structure.
8. Supply oil and tighten plug (13) with O-ring (14).
PC360LC-10 50-153
Disassembly and assembly of idler cushion (PC300-DTBP-926-K-00-A)
a Special tools a Load at installed length of spring:

236 kN {24,082 kg}
Necessity
Symbol
Q'ty
Part No. Part name
791-685-8006 Compressor t 1
791-635-3160 Extension t 1
1 Cylinder
790-101-1600 t 1
(686 kN {70 ton})
M 790-101-1102 Pump t 1
790-201-1990 Plate t 1
2 790-101-5021 Grip t 1
01010-50816 Bolt t 1
k Since the load at installed length of the

2) Apply hydraulic pressure gradually to
spring is large and dangerous, set the recoil
compress the spring and remove lock plate
spring assembly securely to the tool.
(3) and nut (4).
a Figure of structure a Compress the spring until the nut
becomes loose.
a Release the hydraulic pressure slowly to
release the tension of the spring.
a Free length of spring: 659 mm
3) Remove yoke (6), cylinder (7), collar (8), and
dust seal (9) from spring (5).
3. Further disassembly of the piston assembly
1) Remove lock plate (11) from piston assembly
(10), then remove valve (12).
2) Remove snap ring (13), then remove U-
packing (14) and ring (15).
Disassembly (PC300-DTBP-530-K-00-A)
1. Remove piston assembly (2) from idler cushion

assembly (1).
2. Disassembling idler cushion
1) Set idler cushion assembly (1) on tool M1.
50-154 PC360LC-10
2 Sliding surface of cylinder:

Assembly (PC300-DTBP-710-K-00-A)
Grease (G2-LI)
3) Apply hydraulic pressure slowly to compress

the spring, and then tighten nut (4) so that
the installed length of the spring is dimension
(a) and secure it with lock plate (3).
a Installed length (a) of spring: 659 mm
1. Assembly of piston (2)

1) Install ring (15) and U-packing (14) to piston
assembly (10) and secure them with snap
ring (13). 4) Remove idler cushion assembly (1) from tool
2) Tighten valve (12) lightly, and secure it with M1.
lock plate (11). 3. Install piston assembly (2) to the idler cushion
2. Assembly of idler cushion assembly (1).
1) Using tool M2, install dust seal (9) to cylinder 2 Sliding surface of cylinder:
(7).
Grease (G2-LI)
2 Wear ring:
Grease (G2-LI)
a Install the piston assembly with the valve
installed position facing outward.
a Pump 180 cc of grease (G2-LI) into the
cylinder and bleed air. Check that grease
comes out of the grease hole.
2) Install cylinder (7), collar (8), and yoke (6) to

spring (5), and install the assembly to tool
M1.
PC360LC-10 50-155
Disassembly and assembly of track roller (PC300-DTD0-926-K-00-A)
a Special tools
Necessity
Symbol
Q'ty
Part No. Part name
K 796-670-1010 Installer t 1
a Figure of structure
Assembly (PC300-DTD0-710-K-00-A)
1. Using push tool [1], press fit bushings (9) and

(10) to roller (4).
2. Install O-ring (11), install collar (8) to shaft (5)
and install pin (7).
3. Using tool K, install floating seal (6a) to collar

(8).
Disassembly (PC300-DTD0-530-K-00-A) figure) of the floating seal and the O-ring.
1. Remove pin (1), then remove collar (2). a Take care that dirt dose not stick to the
2. Remove floating seals (3) from collar (2) and contact face of the floating seal.
roller (4).
a After inserting the floating seal, check that
3. Pull out roller (4) from shaft (5) and collar (8)
assembly.
a Since approx. 250 to 280 cc of oil is filled in, mm.
drain it at this timing, or underlay some cloth 4. Using tool K, install floating seals (6b) and (3b)
against any careless smearing. to roller (4).
4. Remove floating seals (6) on the other side from
roller (4), and the assembly of shaft (5) and
collar (8).
5. Remove pin (7) and then collar (8) from shaft (5).
6. Remove bushings (9) and (10) from roller (4).
50-156 PC360LC-10
a As to precautions for installation of floating

seals (6b) and (3b), refer to a marked
comments in step 3.
9. Apply standard pressure to roller oil filler port,

and check leakage of air from seal.
a Standard pressure: 0.1 MPa {1 kg/cm2 }
5. Install shaft (5) to roller (4). 10.Fill track roller assembly with oil, then tighten
6. Turn over the assembly of roller (4) and shaft plug (13).
(5).
5 Amount of oil to be sealed (EO30-DH):
250 to 280 cc
3 Plug (13):
10 to20 Nm {1 to 2 kgm}
a When mounting the track roller assembly on
the machine, make sure that plug (13) faces
outward.
7. Using tool K, install floating seal (3a) to collar

(2).
a As to precautions for installation of floating
seals (3a), refer to a marked comments in
step 3.
on it.
8. Install O-ring (12), then install collar (2) to shaft
(5) with pin (1).
PC360LC-10 50-157
Disassembly and assembly of carrier roller (PC290-DTJ0-926-K-00-A)
a Special tools
Necessity
Symbol
Q'ty
L 791-430-3230 Installer t 1
• Sectional view
a A number in the drawing is the number shown in
the text.
3. Remove plate (8) from roller (1).

4. Pull shaft (7) out of roller (1).
Disassembly (PC290-DTJ0-530-K-00-A)
1. Remove plug (11) and drain the oil from the

carrier roller assembly.
5. Remove floating seal (5) from shaft (7).
6 Carrier roller: 145 to 155 cc
a Take care not to damage the sealing surface.
6. Remove ring (4) from shaft (7).
7. Remove floating seal (6) from roller (1).
2. Remove cover (9) from roller (1).

a O-ring (10) is provided on cover (9).
8. Using push tool, remove bushings (2) and (3)
from roller (1).
• Press-fitting force (reference):
Bushing (2): 32 to 67 kN {3,300 to 6,800 kg}
Bushing (3): 26 to 54 kN {2,700 to 5,500 kg}
50-158 PC360LC-10
Assembly (PC290-DTJ0-710-K-00-A)
1. Bushing
1) Using push tool, press fit bushing (2) to roller
(1).
2) Reverse roller (1) and press fit bushing (3)
using push tool.
• Press-fitting force (reference):
Bushing (2): 32 to 67 kN {3,300 to 6,800
kg}
Bushing (3): 26 to 54 kN {2,700 to 5,500
kg}
2. Floating seal
3. Insert shaft (7) to roller (1), then install plate (8).
1) By using tool L, install floating seal (5) to ring
(4). a Apply oil to the sliding surface of the floating
2) Using tool L, install floating seal (6) to roller seal, and take care not to have any dirt stuck
(1). on it.
a When installing the floating seal, • End play in axial direction of roller (1): 0.5 to
completely clean, degrease and dry the 0.7 mm
contact surfaces (hatched part) of the O-
ring and floating seal. Take care that dirt
dose not stick to the contact face of the
floating seal.
a When installing floating seals, use tool L
and make sure to press the O-ring.
a After installing the floating seals, check
that the inclination is less than 1 mm and
the protrusion (a) is within the range of 5
to 7 mm.
PC360LC-10 50-159
4. Press fit ring (4) to the shaft by using push tool 8. Fill carrier roller assembly with oil and tighten
[1] until the height difference between roller (1) plug (11).
and ring (4) becomes 3 ± 0.2 mm.
5 Carrier roller: 145 to 155 cc (EO30-DH)
a Use push tool [2] to support shaft (7).
• Press-fitting force: 22 to 25 kN {2.2 to 2.5
ton}
a Be careful not to give any impact until
installing cover (10) so that press-fitted ring
(4) may not move out.
5. Install ring (10) to cover (9).

6. Install cover (9) to roller (1).
7. Apply standard pressure to roller oil filler port,

and check leakage of air from seal.
a Standard pressure: 0.1 MPa {1 kg/cm2}
50-160 PC360LC-10
Removal and installation of revolving frame assembly (PC220-H110-924-K-00-A)

the work equipment to the ground, and stop
the engine.

a Note connector numbers and installed positions

before disconnecting wirings and hoses.
a Fit a plug or flange to the disconnected hydraulic
hose to prevent oil from flowing out. 7. Disconnect hoses (6) to (12) of center swivel
Removal (PC300-H110-520-K-00-A)
joint (5).
• Hose (6): between center swivel joint (port D)
1. Remove the work equipment assembly, referring
and swing motor (port T)
to "Removal and installation of work equipment
• Hose (7): between center swivel joint (port D)
assembly".
and hydraulic tank
2. Remove the counterweight assembly, referring
• Hose (8): between center swivel joint (port E)
to "Removal and installation of counterweight
and solenoid valve
assembly".
• Hose (9): between center swivel joint (port B)
3. Remove the engine hood assembly, referring to
and left travel control valve (port B2)
"Removal and installation of engine hood
• Hose (10): between center swivel joint (port
assembly".
D) and right travel control valve (port B5)
4. Disconnect hose (1) of the boom cylinder.
A) and left travel control valve (port A2)
C) and right travel control valve (port A5)
8. Pull out pin (13) from center swivel joint (5) to
disconnect stopper plate (14) from center swivel
joint (5).
a Remove the cotter pin at the lower end of pin
(13) beforehand.
5. Sling the boom cylinder assembly (2).

6. Remove plate (3) and pin (4), then sling and
remove boom cylinder assembly (2).
3 Boom cylinder assembly (2):
260 kg
9. Set slings to revolving frame assembly (15).

a Use two of the holes for counterweight
mounting bolts and two of the holes for the
boom cylinder foot pins to lift revolving frame
assembly (15) at 4 places.
10.Remove 35 mounting bolts (16), then sling and
remove revolving frame assembly (15). [*1]
PC360LC-10 50-161
a Leave two or three mounting bolts each at

front and rear. Balance revolving frame
assembly (15) in front, rear, right and left with
lever blocks etc., and then remove the
remaining bolts.
a Sling revolving frame assembly (15) slowly
take care not to let it hit against center swivel
joint (5).
4 Revolving frame assembly (15):

6,600 kg

removal.
[*1]
2 Swivel circle mating surface:
2 Threads of revolving frame mounting
bolt:
Adhesive (LT-2)
3 Revolving frame assembly mounting
bolt:
981 to 1,177 Nm {100 to 120 kgm}
• Refilling of oil (Hydraulic tank)
• Bleeding air
hydraulic system".
50-162 PC360LC-10
Removal and installation of counterweight assembly (PC300-H700-924-K-00-A)
a Special tools
Necessity
Symbol
Q'ty
Part No. Part name
Commercially Impact wrench

1 q 1
available
Z Socket wrench
Commercially (width across flats:
2 q 1
available 55 mm)

the engine.

Removal (PC300-H700-520-K-00-A)
1. Open the side cover on the left side of the a When shims are inserted, check their
machine and disconnect intermediate connector locations and quantities.
A40 (1) of the rear view camera.
5. Sling and remove counterweight assembly (4).

2. Disconnect connector L09 (2) of rear working [*2]
lamp
a Take care that the counterweight will not
touch the machine.
4 Counterweight assembly (4):

7,100 kg
3. Set slings to the counterweight assembly.

4. By using tools Z1 and Z2, remove four mounting
bolts (3). [*1]
PC360LC-10 50-163
Reference: Removal of rear view camera

assembly
4. Disconnect rear view camera connector A45

(10) and remove rear view camera assembly
(11).
2. Remove bolts (8) to remove cover (6). [*3]

a For bolts using shims (7), check their
locations and the quantities of shims.
(Shims (7) are put on cover (6), be careful
not to drop them.)
3. Remove two bolts (9).
50-164 PC360LC-10
• Perform installation in the reverse order to removal.

[*1]
a Precautions for tightening mounting bolts
Tighten the mounting bolts lightly by hand (with a hand wrench) until the mounting faces of the
counterweight are seated.
Then, tighten to the specified torque with a large-sized impact wrench.
2 Threaded portion of counterweight assembly mounting bolt:
Adhesive (LT-2)
3 Counterweight assembly mounting bolt:
2,450 to 3,040 Nm {250 to 310 kgm}
[*2]
Install soundproof sheets for counterweight according to the following procedure.
• Attach soundproof sheets for counterweight according to the following procedure.
• Attach soundproof sheets (1), (2), (3), (4), (5), (6), (7), and (8) to the machine forward side of the
counterweight.
a1: (420) a6: (480) b1: (780) b6: (710) c1: 250
a2: 690 a7: 128 b2: (21) b7: 26 c2: 250
a3: (575) a8: 99 b3: (775) b8: (750)
a4: (305) a9: 84 b4: 26 b9: 1,176.4
a5: (450) b5: (820)
• Remove the grease and rust completely from the surface of counterweight which soundproof sheets are
attached to.
• Install the soundproof sheet with surface (a) which is without SG sheet (black surface) facing downward.
PC360LC-10 50-165
Installing and adjusting counterweight

a Install counterweight (4) so that the clearances
between side cover (12) and counterweight (4),
and revolving frame (13) and counterweight (4)
in the direction of front and rear are even and
within the limit of 10 ± 5 mm. However, the
difference between the clearance at point S and
the clearance at point T must be 3 mm or less.
a The horizontal clearance (a) in right to left
direction between side cover (12) and
counterweight (4) must be 9 ± 4 mm.
a The horizontal clearance (b) in right to left
direction between revolving frame (13) and
counterweight (4) must be 5 mm or less.
a The vertical clearance (c) between upper cover
(14) and counterweight (4) must be 5 mm or
less.
a Reference figure (Enlarged view of R.H. side
seen from rear of the machine)
[*3]
Installation and adjustment of rear view camera
cover
a Using shims (7), adjust the vertical clearance
between the counterweight and cover (6) to 2
mm or less.
a Hook shim (7) to cover (6) or insert it from
outside after inserting the bolt temporarily.
50-166 PC360LC-10
Hydraulic system
Removal and installation of center swivel joint assembly (PC220-J8E0-924-K-00-A)
k Park the machine on a level ground, lower • Hose (12): between center swivel joint (port
the work equipment to the ground, and stop E) and solenoid valve
the engine. • Hose (13): between center swivel joint (port
B) and left travel control valve (port B2)
k Release the remaining pressure in the • Hose (14): between center swivel joint (port
hydraulic circuit. For details, see Testing and D) and right travel control valve (port B5)
adjusting, "Releasing remaining pressure • Hose (15): between center swivel joint (port
from hydraulic circuit". A) and left travel control valve (port A2)
a Note connector numbers and installed positions C) and right travel control valve (port A5)
before disconnecting wiring and hoses. 3. Pull out pin (17) from center swivel joint (9) to
a Fit a plug or flange in the place of the hydraulic disconnect stopper plate (18) from center swivel
hose is disconnected from to prevent oil from joint (9).
flowing out. a Remove the cotter pin at the lower end of pin
(17) beforehand.
Removal (PC300-J8E0-520-K-00-A)
1. Disconnect eight hoses (1) to (8) between the

center swivel joint and travel motor.
• Hose (1): between center swivel joint (port C)
and right travel motor (port PA)
• Hose (2): between center swivel joint (port A)
and left travel motor (port PB)
and right travel motor (port P)
and left travel motor (port P)
• Hose (5): between center swivel joint (port T)
and right travel motor (port T) 4. Remove four mounting bolts (19) of center
• Hose (6): between center swivel joint (port T) swivel joint (9). [*1]
and left travel motor (port T)
• Hose (7): between center swivel joint (port D) a Do not remove center swivel joint base (20).
and right travel motor (port PB) a When removing center swivel joint base (20),
• Hose (8): between center swivel joint (port B) make a mark to indicate its original position
and left travel motor (port PA) and direction. [*3]
2. Disconnect hoses (10) to (16) of center swivel 5. Sling and remove center swivel joint (9). [*2]
joint (9).
D) and swing motor (port T)
D) and hydraulic tank
PC360LC-10 50-167
Hydraulic system
• (9): Center swivel joint

4 Center swivel joint:
• (24): Sprocket
45 kg
Installation (PC300-J8E0-720-K-00-A)
• Perform installation in the reverse order to level. Run the engine to circulate the oil through
removal. the system. Then, check the oil level again.
[*1]
If center swivel joint base (20) was removed, install 5 Hydraulic tank:
it, four bolts (21), eight washers (22), and four nuts 365 l
(23) to the dimensions shown in the figure to set
• Bleeding air
center of swing (C).
hydraulic system".
[*2]
Install center swivel joint (9) with its port (B) and (D)
side toward the front of the machine (in the direction
of the arrow).
(The figure shows the top view of the machine.)
50-168 PC360LC-10
Hydraulic system
Disassembly and assembly of center swivel joint (PC300-J8E0-926-K-00-A)
a Special tools
Necessity
Symbol
Q'ty
Part No. Part name
790-101-2501 Push-puller t 1
790-101-2510 • Block 1
790-101-2520 • Screw 1
791-112-1180 • Nut 1
S 790-101-2540 • Washer 1
790-101-2630 • Leg 2
790-101-2570 • Plate 4
790-101-2560 • Nut 2 Assembly (PC300-J8E0-710-K-00-A)
790-101-2650 • Adapter 2 1. Install slipper seal (9) and O-ring (8) to swivel
a Configuration drawing rotor (4).
2. Install cover (7) to swivel shaft (5).
2 Inside of cover:
Grease (G2-LI) (apply 2 to 3 cc)
3. Install dust seal (6) to cover (7).
2 Dust seal lip:
Grease (G2-LI) (apply 2 to 3 cc)
4. Place swivel shaft (5) on the block. Using the
push tool, install swivel rotor (4) to the shaft
while tapping the swivel rotor lightly with a
plastic hammer.
2 Contact surfaces on rotor and shaft:
Grease (G2-LI)
a When installing the rotor, be extremely
careful not to damage the slipper seal and
the O-ring.
5. Install ring (3) and secure it with snap ring (2).
6. Fit the O-ring and install cover (1).
3 Mounting bolt:
31.4 ± 2.9 Nm {3.2 ± 0.3 kgm}
Disassembly (PC300-J8E0-530-K-00-A)

2. Remove snap ring (2).
3. By using tool S, pull swivel rotor (4) and ring (3)
out of swivel shaft (5).
4. Remove dust seal (6) from cover (7).
5. Remove O-ring (8) and slipper seal (9) from
swivel rotor (4).
PC360LC-10 50-169
Hydraulic system
Removal and installation of hydraulic tank assembly (PC220-PM30-924-K-00-A)

the engine.


a Fit a plug or flange to disconnected hydraulic
hose to prevent oil from flowing out. 7. Disconnect hydraulic hoses (8), (9), (10), and
Removal (PC300-PM30-520-K-00-A)
(11) at the inside upper part of the hydraulic
tank.
1. Swing the upper structure counterclockwise by
45 ° and stop it, and then remove undercovers
(1) and (2).
a The upper structure must be swung in
advance to remove the hydraulic tank
mounting bolts.
8. Disconnect hydraulic hoses (12), (13), (14), (15)

and (16) at the inside lower part of the hydraulic
tank.
2. Remove drain plug (3) to drain oil from the

hydraulic tank. [*1]
6 Hydraulic tank:
365 l

the work.

6. Remove control valve covers (7).
50-170 PC360LC-10
Hydraulic system
11.Disconnect hose clamp (19). 17.Set slings to hydraulic tank assembly (23) and
12.Disconnect hydraulic oil temperature sensor remove four mounting bolts (26) on right and left
connector CN-P22 (20). sides each.
13.Remove two mounting bolts (21) and cushion
(22).
a Place an oil container under suction tube
(22).
14.Remove suction tube (22) from hydraulic tank
assembly (23). [*1]
18.Sling and remove tank assembly (23).
4 Hydraulic tank assembly (23):

190 kg
Installation (PC300-PM30-720-K-00-A)
15.Remove bracket (24). • Perform installation in the reverse order to

16.Remove hydraulic tank cover (25). removal.
[*1]
1. Install suction tube (22) to hydraulic tank
assembly (23) according to the following
procedure.
1) Apply adhesive to the inserted portion (j) of
the suction hose (hatched area).
PC360LC-10 50-171
Hydraulic system
2 Inserted portion (j) of the suction

hose (hatched area):
Liquid adhesive (ThreeBond 4314
or equivalent)

again.
2) Install the hose clamps according to the
following procedure. 5 Hydraulic tank (Hydraulic oil):
a Installation order: (a) o (b) o (c) o (d) 365 l
(For details, see "Table of fuel, coolant
and lubricants")
• Bleeding air (hydraulic system)
hydraulic system".
2. Install the MIKALOR clamp according to the

• With bridge (BR) set under the clamp bolt,
tighten the bolt so that bridge (BR) laps over
with the band by dimension (b) indicated
below.
Dimension (b): Min. 5 mm
Lubricant oil (ThreeBond PANDO
18B or equivalent)
Install the clamp to the clamp mark put on
the hose.
3 Clamp bolt:
16 to 17 Nm {1.6 to 1.7 kgm}
Tighten until dimension (BDG) becomes as
follows.
BDG: 12 to 15 mm
50-172 PC360LC-10
Hydraulic system
Removal and installation of main pump assembly (PC300-C200-924-K-00-A)
a Special tools
6 Hydraulic tank:
Necessity
365 l
Symbol
Q'ty
Part No. Part name
1 796-460-1210 Oil stopper q 1

R
2 796-770-1320 Adapter q 1

the upper structure by 45 ° clockwise, lower
stop the engine.

hydraulic circuit. For details, see Testing and a If using tool R1 and R2, remove the hydraulic
adjusting, "Releasing remaining pressure tank strainer and stop oil with tool R1 and
from hydraulic circuit". R2.

a Attach tags to the hoses to show their installed

positions to prevent any mistake when installing.
Removal (PC300-C200-520-K-00-A)
1. Remove undercovers (1) and (2).

3. Remove drain plug (4) and drain the damper oil.
6 Damper case:
1.3 l
2. Remove drain plug (3) and drain the hydraulic

oil.
4. Removal of covers
1) Open the side cover on the left side of the
machine and remove KDPF water drain tube
(5). [*1]
PC360LC-10 50-173
Hydraulic system
• Connector P28 (13): rear pump swash plate

sensor
• Connector V12 (14): rear PC-EPC valve
6. Disconnect hoses (15) to (17).
• Hose (15): front LS pressure (band: none)
• Hose (16): rear LS pressure (band: red)
• Hose (17): drain port hose
2) Remove covers (6), (7), and (8).
7. Disconnect connectors (18) and (19).

• Connector V11 (18): front PC-EPC valve
• Connector V19 (19): LS-EPC valve
8. Disconnect hoses (20) to (25).
• Hose (20): front pump pressure (band: none)
• Hose (21): rear pump pressure (band: red)
3) Remove frame (9). • Hose (22): additional pilot filter
• Hose (23): PC-EPC source pressure (band:
yellow)
• Hose (24): front pump delivery port
• Hose (25): rear pump delivery port
4) Remove covers (10) and (11).
9. Disconnect connector (26).

10.Disconnect six wiring harness clamps (27)
around the main pump.
12.Remove four mounting bolts (29) and
disconnect pump suction tube (30).
5. Disconnect connectors (12) to (14).

• Connector P27 (12): front pump swash plate
sensor
50-174 PC360LC-10
Hydraulic system
4 Main pump assembly (34):

225 kg
13.Remove the tube clamp and damper case oil

filler pipe (31). [*2]
14.Remove blocks (32) and (33) to sling main
pump assembly (34).
Installation (PC300-C200-720-K-00-A)

removal.
[*1]
a Insert and install KDPF water drain tube (5) into
I-joint (38) of the KDPF assembly.
• Tube insertion length (A): 31.5 mm
15.Remove bolt (35) at the center of gravity of main

pump assembly (34).
[*2]
3 Joint bolt of damper case oil filler pipe
(31):
127 to167 Nm {13 to 17 kgm}
16.Install eyebolt [1].

a As eyebolt [1], do not use one installed to
main pump assembly (34) but use a one of
sufficient size which withstands the load.
17.Set wire [2] to main pump assembly (34) and
remove mounting bolt (36).
a Sling main pump assembly (34) by one point.
Install auxiliary holding rope [3] to eyebolt
(37) to prevent the main pump assembly
from turning and eyebolt [1] from coming off.
18.Sling and remove main pump assembly (34). [*3]
[*3]
PC360LC-10 50-175
Hydraulic system
2 Main pump involute splines:

2 Mating face on main pump case:
a Take care not to torque the bolts excessively
since the flywheel housing is made of aluminum.
• Refilling with oil (damper case)
Refill hydraulic oil through the oil filler port to the
specified level.
5 Damper case:
1.3 l
3 Damper case drain plug:
58.8 to 78.4 Nm {6 to 8 Nm}
5 Hydraulic tank:
365 l
3 Hydraulic tank drain plug:
75 ± 8 Nm {7.65 ± 0.8 kgm}
• Bleeding air
hydraulic system".
50-176 PC360LC-10
Hydraulic system
Removal and installation of control valve assembly (PC300-C030-924-K-00-A)
a Special tools
6 Hydraulic tank:
Necessity
365 l
Symbol
Q'ty
Part No. Part name
1 796-460-1210 Oil stopper q 1

R
2 796-770-1320 Adapter q 1
k Park the machine on a level surface, lower

the work equipment to the ground so that it
is stable, and stop the engine.

adjusting, "Releasing remaining pressure a If using tool R1 and R2, remove the hydraulic
from hydraulic circuit". tank strainer and stop oil with tool R1 and
R2.
a Attach tags to the hoses to show their installed

positions to prevent any mistake when installing.
Removal (PC300-C030-520-K-00-A)
1. Remove undercovers (1) and (2).

from the KVGT. [*1]
5. Remove step (6).
2. Remove drain plug (3) and drain the hydraulic

oil.
7. Remove KCCV ventilator assembly (8). For

assembly".
8. Remove control valve top cover (9).
9. Remove air cleaner top cover (10) according to
PC360LC-10 50-177
Hydraulic system

(11).
frame (12).
15.Disconnect hose (18).

16.Disconnect tube bracket (19).
17.Remove attachment hoses (20) and (21).
18.Sling and remove bracket (22).
10.After removing the air cleaner top cover, cover 4 Bracket:

the air inlet of the air cleaner with a vinyl sheet 60 kg
etc.
11.Remove frames (13).
12.Remove covers (14) and (15).
19.Disconnect the following hoses on the top of the

control valve.
• Hose (23): 2-stage relief solenoid valve
• Hose (24): swing holding brake solenoid
13.Loosen hose clamp (16) and remove air intake valve
hose (17) from air cleaner (11). [*2] • Hose (25): Travel junction solenoid valve
14.After removing the air intake hose, cover the air • Hose (26): PPC oil pressure lock solenoid
inlet of air cleaner (11) with a vinyl sheet etc. valve
• Hose (27): port PPS1 (band: none)
• Hose (28): port PLS2
• Hose (29): port PLS1
50-178 PC360LC-10
Hydraulic system
• Hose (30): swing cutoff solenoid valve
23.Disconnect the following connectors on the rear

of the control valve. [*3]
20.Disconnect the following hoses of the junction
block. • Connector (53): merge-divider EPC valve
(V23) (Band: Red)
• Hose (31): bucket CURL (band: white)
• Connector (54): merge-divider EPC valve
• Hose (32): boom LOWER (band: brown)
(V24) (band: white)
• Hose (33): swing RIGHT (band: none)
• Connector (55): front pump pressure sensor
• Hose (34): arm IN (band: blue)
(P25)
• Hose (35): bucket DUMP (band: black)
• Hose (36): boom RAISE (band: green)
• Hose (37): swing LEFT (band: red)
• Hose (38): arm OUT (band: yellow)
21.Disconnect the following connectors of the
junction block.
• Connector (39): bucket CURL sensor (P01)
• Connector (40): boom LOWER sensor (P02)
• Connector (41): swing RIGHT sensor (P07)
• Connector (42): arm IN sensor (P04)
• Connector (43): bucket sensor (P05)
• Connector (44): boom RAISE sensor (P06)
• Connector (45): swing LEFT sensor (P03)
• Connector (46): arm OUT sensor (P08) 24.Disconnect the following hoses on the right of
control valve.
• Hose (56): port P-4 (band: yellow)
• Hose (57): port P4 (band: red)
• Hose (58): port P10 (band: green)
22.Disconnect following hoses from the rear of

control valve.
• Hose (47): port PP1
• Hose (48): port PP2
• Hose (49): port PPS2 (band: red) 25.Disconnect the following connectors on the right
• Hose (50): port PR of the control valve.
• Hose (51): port T
• Connector (59): PPC lock solenoid valve
• Hose (52): port P
(V01)
• Connector (60): swing 2-stage relief solenoid
valve (V02)
PC360LC-10 50-179
Hydraulic system
• Connector (61): travel junction solenoid valve

(V03)
• Connector (62): travel speed increase
solenoid valve (V04)
• Connector (63): swing holding brake
• Connector (64): machine pushup solenoid
valve (V06)
• Connector (65): 2-stage relief solenoid valve
(V08)
• Connector (66): attachment circuit selector
28.Disconnect the following hoses and tubes on the
front of control valve.
• Hose (18): port B-2
• Hose (70): port T1
• Hose (71): port P9
• Hose (72): port PX2
• Hose (73): port B6
• Hose (74): port B-1
• Hose (75): port A-1
• Hose (76): port TSW
• Tube (77): port A-2
29.Disconnect the following hoes and tubes.

26.Disconnect four boom cylinder hoses (67). • Hose (78): port B1
27.Remove boom tube mounting clamps (68) and • Hose (79): port B2
(69). • Tube (80): port B3
• Tube (83): port B6
• Tube (84): port A-1
• Tube (85): port A1
• Hose (86): port A2
50-180 PC360LC-10
Hydraulic system
30.Disconnect the following hoses on the bottom of 34.Sling and remove control valve assembly (98).
control valve.
a Lift control valve assembly (98) while
• Hose (91): port TS keeping it horizontal.
• Hose (92): port TS
a Check that all wiring harness connectors and
hoses are disconnected.
4 Control valve assembly:

330 kg
31.Disconnect the following hoses and tubes on the

rear of the control valve.
• Hose (93): port T
• Tube (94): port T
32.Disconnect the following connectors.
• Connector (95): rear pump pressure sensor Installation (PC300-C030-720-K-00-A)
(P26) • Perform installation in the reverse order to
• Connector (96): variable back pressure EPC removal.
valve (V25) [*1]
3 Hose clamp:
10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}
14.7 to 44.1 Nm {1.5 to 4.5 kgm}
[*2]
3 Air cleaner hose clamp fastening bolt:
10.5 ± 0.5 Nm {1.1 ± 0.05 kgm}
33.Set slings to the control valve assembly and the system. Then, check the oil level again.
remove four mounting bolts (97) from the
bottom. 5 Hydraulic tank:
365 l
PC360LC-10 50-181
Hydraulic system

hydraulic system".
50-182 PC360LC-10
Hydraulic system
Disassembly and assembly of control valve (PC300-C030-926-K-00-A)
a This section explains only the precautions for

assembling the contol valve assembly.
Replacing procedures of pressure
compensation valve seal (PC300-L6D4-924-K-
a Special tools 00-A)
a Since many types of pressure compensation
Necessity
Symbol
valve are used in the machine, put a mark and
Q'ty
Part No. Part name note the installed position when removing it.
1. Remove piston (2), plug (3) and spring (4) from
796-946-1310 Guide f 21.8 mm pressure compensation valve (1).
(For 723-46-40100 and 723-46- t 1 2. Remove seals (5) and (6) from piston (2).
40601)
796-946-1410 Guide f 21.6 mm
t 1
(For 723-46-47500)
796-946-1810 Guide f 21.2 mm
1 (For 723-46-43100 and 723-46- t 1
43400)
796-946-2110 Guide f 20.9 mm
t 1
(For 723-46-44100)
796-946-2210 Guide f 20.6 mm
(For 723-46-45100 and 723-46- t 1
45700)
796-946-1320 Guide f 21.8 mm
(For 723-46-40100 and 723-46- t 1
a Many types of pistons are used.
40601)
3. Set tool T1 to piston (2) and push in seal (5)
796-946-1420 Guide f 21.6 mm slowly with the hands so that it expands evenly.
t 1
(For 723-46-47500)
a You may push in the seal to the flat portion of
796-946-1520 Guide f21.6 mm the tool, and then install the tool to the piston
t 1
(For 723-46-42800) to push in the seal further.
T 2 796-946-1820 Guide f 21.2 mm
(For 723-46-43100 and 723-46- t 1
43400)
796-946-2120 Guide f 20.9 mm
t 1
(For 723-46-44100)
796-946-2220 Guide f 20.6 mm
(For 723-46-45100 and 723-46- t 1
45700)
796-946-1330 Sleeve
(For 723-46-40100 and 723-46- t 1
40601)
796-946-1430 Sleeve
(For 723-46-42800 and 723-46- t 1
47500) 4. Repeat the same process to install another seal
796-946-1830 Sleeve (6). Set tool T2 to piston (2) from the same
3 t 1 direction and push in seal (6) slowly so that it
(For 723-46-43100 and 723-46-
43400) expands evenly.
796-946-2130 Sleeve
t 1
(For 723-46-44100)
796-946-2230 Sleeve
(For 723-46-45100 and 723-46- t 1
45700)
PC360LC-10 50-183
Hydraulic system
a You may push in the seal to the flat portion of

the tool, and then install the tool to the piston
Assembly of control valve (PC300-C030-530-
K-00-A)
to push in the seal further.
5. Install settling tool T3 to piston (2) and keep it a Apply engine oil (EO30-DH or equivalent) to the
installed for approx. 1 minute so that seals (5) sliding surfaces on the parts before assembling
and (6) fit in. them.
a Check the seals for protrusion and cut.
6. Fit plug (3) and spring (4) to piston (2), then

install pressure compensation valve (1).
a After the installation, push piston (2) with the
hand and check that it is returned by only the
spring force.
50-184 PC360LC-10
Hydraulic system
a When installing spools (7) and (8) into the a Install filters (9) at the bottom of ports PLS1 (e)
cylinder, ensure that its drilled holes (a) and (b) and PLS2 (f) in the directions shown below.
face in the direction of cylinder ports (c) and (d). (Take care of the positions of punched portions
(10))
a When installing, apply liquid adhesive to the

mating face of each block. However, do not
apply the liquid adhesive to the following parts.
• Boom drift prevention valve
• Boom Hi check valve
• Variable back pressure valve
• Arm quick return valve
• Arm drift prevention valve
2 Mating faces of each block of control
valve:
Loctite 222 or equivalent
a Installation of the control valve top cover
Fit two washers each to cylinder port side bolts
(11), and one washer each to pump port side
bolts (12).
a Tighten the mounting bolts for the following parts
in the order shown below. (AoDoCoB)
• Merge-divider valve
• Boom Hi check valve
• Boom drift prevention valve
• Variable back pressure valve
• Control valve upper cover
• Control valve lower cover
PC360LC-10 50-185
Hydraulic system
3 Merge-divider valve (13) mounting bolt:

156.9 to 176.5 Nm {16 to 18 kgm}
3 Mounting bolts for control valve upper
and lower covers:
156.9 to 176.5 Nm {16 to 18 kgm}
50-186 PC360LC-10
Hydraulic system
a When slinging the control valve assembly, use

tapped holes (g) or (h).
• Tapped hole (g): M10 x 1.5 mm
• Tapped hole (h): M12 x 1.75 mm
• Pressure compensation valve

a Install each pressure compensation valve,
checking the mark that was put when it was
removed.
3 Pressure compensation valve:
372.7 to 411.9 Nm {38 to 42 kgm}
• Main relief valve assembly
a After installing the main relief valve to the
control valve, test and adjust it. For details,
see Testing and adjusting, "Measuring and
adjusting oil pressure in work equipment,
swing, and travel circuits".
3 Main relief valve assembly:
49 to 58.8 Nm {5 to 6 kgm}
PC360LC-10 50-187
Hydraulic system
Disassembly and assembly of work equipment PPC valve (PC300-PL28-926-K-00-A)
Disassembly (PC300-PL28-530-K-00-A)
a Only precautions for disassembling the work

equipment PPC valve assembly are described
below.
a Pairs of springs (4) and (5) have different loads
at installed length. Put tags to indicate their
mounting position (hydraulic port) so that they
can be installed later in the correct position.
Assembly (PC300-PL28-710-K-00-A)
a Only precautions for assembling the work • Installed height of all springs: 31.9 mm
equipment PPC valve assembly are described • Load at installed length
below. Spring (4) (P1, P2): 35.3 N {3.6 kg}
Spring (5) (P3, P4): 21.6 N {2.2 kg}
a Before assembly, thoroughly clean the parts and
check them for any dirt, rust or damage to a Before installing piston (6), apply grease (G2-LI)
prevent failures. to the periphery of the piston and the bore in the
valve body.
a Install spring (3) with its small diameter end
toward shim (2). 3 Bolt (9):
• Diameter of spring (inside diameter) 11.8 to 14.7 Nm {1.2 to 1.5 kgm}
Small diameter side: f4.9 mm
a When installing joint (10) to valve body (1), apply
Large diameter side: f5.55 mm
Loctite according to the following procedure.
a When installing springs (4) and (5), note that 1. When installing the joint, apply a drop
their installed positions are determined by the (approximately 0.02 g) of Loctite (No. 262) to
hydraulic ports. two places at threaded hole (A) in the valve body.
50-188 PC360LC-10
Hydraulic system
Before installing the joint, thoroughly degrease

and dry its male threads and the threaded hole
in the valve body by using denatured alcohol.
2. Drop LOCTITE to the following positions.
2 Female threads of body (A):
Loctite No. 262
3 Joint (10):
39 to 49 Nm {4 to 5 kgm}
a Apply grease (G2-LI) to the rocking parts of

joint (10) and to the contact surfaces on disc
(11) and piston (6).
2 Quantity of grease (G2-LI)
• Rocking parts of joint: 2 to 4 cc/all periphery
• Contact surfaces of disc and piston: 0.3 to
0.8 cc/part
a For installation of disc (11), see Testing and
adjusting, "Adjusting play of work equipment
and swing PPC valve"
a Lever play:
0.5 to 3 mm (at 200 mm from lever pivot
point)
3 Nut (12):
69 to 88 Nm {7 to 9 kgm}
PC360LC-10 50-189
Hydraulic system
Disassembly and assembly of travel PPC valve (PC300-C6V0-926-K-00-A)
Disassembly (PC300-C6V0-530-K-00-A)
1. Remove screw (19) and remove damper

assembly (18).
2. Remove mounting bolts (17) and remove case
(16), shaft (15) and lever (13) as a unit.
3. Remove mounting bolts (11) to remove plate
(10).
a Recode the thickness and installed position
of each washer (12).
a Remove pin (21) from valve body (1).
4. Remove seal (9) and collar (8).
5. Remove pistons (7) to remove retainers (6),
springs (5) and (4) and shims (3).
a Record quantity and thickness of shims (3)
for each installation position before storing
them.
6. Remove valves (2) from valve body (1).
Assembly (PC300-C6V0-710-K-00-A)
a The following describes the precautions for a When installing piston (7), apply grease (G2-LI)
assembling alone. to its periphery and the inside of the valve body
hole.
a Before assembly, throughly clean the parts and
check them for dirt, rust, or damage to prevent a Install spring (4) with its small diameter end
failure. Assemble the parts with utmost care. toward shim (3).
• Diameter of spring (inside diameter)
50-190 PC360LC-10
Hydraulic system
Small diameter side: f4.9 mm

Large diameter side: f5.55 mm
a Apply grease (G2-LI) to the rocking part of shaft
(15), contact parts of lever (13) and piston (7),
and contact parts of damper (18) and pin.
2 Quantity of grease (G2-LI)
Rocking part of shaft (15): 4 to 8 cc (all
periphery)
Connection of lever (13) and piston (7):
0.3 to 0.8 cc (one place)
Connection of damper (18) and pin: 0.3 to
0.8 cc/place
a Assemble washer (12) to thickness (t) = 1.6 mm.
If the difference between the right and left stroke
ends is larger than 0.7 ° , adjust it to less than
0.7 ° by changing the washer thickness.
a Decreasing the washer thickness 0.3 mm, the
stroke end angle increases 0.39 ° .
• Washer (12) thickness (t) setting: 1.0, 1.3,
1.6, 1.9 and 2.2 mm
a The following shows the tightening torque of
each part.
3 Bolt (11):
27 to 34 Nm {2.8 to 3.5 kgm}
3 Bolt (17):
25 to 31 Nm {2.5 to 3.2 kgm}
3 Screw (19):
0.441 to 0.588 Nm {0.045 to 0.06 kgm}
PC360LC-10 50-191
Work equipment
Removal and installation of bucket assembly (PC300-LBK0-924-K-00-A)
k Face the back of the bucket down, lower the

work equipment to the ground, then set the
Installation (PC300-LBK0-720-K-00-A)
lock lever to the LOCK position. • Perform installation in the reverse order to
removal.
Removal (PC300-LBK0-520-K-00-A) [*1]
1. Remove plate (1), then remove pin (2) a When tightening the lock nut, tighten so that
connecting the arm and bucket. [*1][*2] clearance (a) between the plate and nut is as
a Shims are installed on the right side, so shown below.
check and record their thickness and Clearance (a): 0.5 to 1.5 mm
quantity.
4 Pin (2):
30 kg
2. Start the engine, and retract the piston rod, then
tie the link to the arm by using a wire to prevent
the piston rod from coming out.
3. Remove plate (3), then remove pin (4)
connecting the arm and bucket. [*1][*3]
4 Pin (4):
30 kg
4. Start the engine and raise the swing work
equipment, then remove bucket assembly (5). [*2]
2 Inner surface of pin holes:
4 Bucket assembly (5):
Molybdenum disulphide lubricant (LM-P)
1,550 kg
2 Pin after installed in position:
k When aligning the pin holes, never insert
your fingers in the holes.
[*3]
50-192 PC360LC-10
Work equipment
Removal and installation of arm assembly (PC300-L810-924-K-00-A)
Removal (PC300-L810-520-K-00-A)
1. Remove the bucket assembly. For details, see

"Removal and installation of bucket assembly".
2. Secure the linkage to the arm with a wire.
k Extend the arm cylinder piston rod to a

point approximately 200 mm before the
end of the arm IN stroke, then lower the
arm on to block [1] and stand [2]. Set the
lock lever to the LOCK position and stop
the engine.
3. Set block [3] between the arm cylinder and
9. Start the engine, then raise the boom and
boom.
remove arm assembly (7).
4. Remove plate (1) and pull out arm cylinder head
pin (2). [*1]
4 Arm assembly (7):
5. Start the engine, and retract the piston rod, then
tie the cylinder rod to the arm by using a wire to 1,700 kg
prevent the piston rod from coming out.
k Stop the engine, and release the pressure

remaining in the circuit. For details, see
Testing and adjusting, “Releasing
pressure remaining in hydraulic circuit”.
6. Disconnect two bucket cylinder hoses (3).
7. Disconnect two attachment hoses (4).
8. Remove plate (5) and pull out boom top pin (6).
[*2]
4 Pin (6):
80 kg
Installation (PC300-L810-720-K-00-A)

removal.
[*1]
[*2]
PC360LC-10 50-193
Work equipment
Add oil through the oil filler to the specified level.

Run the engine to circulate the oil through the
system. Then, check the oil level again.
5 Hydraulic tank (Hydraulic oil):

Refilling only (For details, see "Table
of fuel, coolant and lubricants")
hydraulic system".
50-194 PC360LC-10
Work equipment
Removal and installation of work equipment assembly (PC300-L410-924-K-00-A)
a Special tools a Remove the boom cylinder on the other side

in the same manner.
Necessity
Symbol
a If bumping of the lifting hook against the
Q'ty
Part No. Part name
working lamp is anticipated in lifting the work
equipment, the lamp must be removed.
796-670-1100 Remover t 1 6. Stop the engine, and release the pressure
796-670-1110 • Sleeve 1 remaining in the circuit. For details, see Testing
796-670-1120 • Plate 1 and adjusting, "Releasing remaining pressure
from hydraulic circuit."
796-670-1130 • Screw 1
7. Remove two attachment hoses (6).
791-775-1150 • Adapter 1
V 8. Disconnect two bucket cylinder hoses (7) and
01643-33080 • Washer 1 three arm cylinder hoses (8).
01803-13034 • Nut 1
Puller (490 kN {50 ton} a Plug the hose and then fix it to the valve side
790-101-4000 long) t 1 with rope.
790-101-1102 Pump (294 kN {30 ton}) t 1 9. Disconnect working lamp intermediate
connector A13 (9).
k Fully extend the arm and bucket and
completely lower the work equipment to the
ground.
Removal (PC300-L410-520-K-00-A)
1. Disconnect grease hose (1).

2. Sling the boom cylinder assembly (2).
3. Remove lock bolt and nut (3). [*1]
4. Remove plate (4) and remove boom cylinder
head pin (5). [*2]
a Shims are installed, so note their quantity 10.Sling work equipment assembly (10), and then
and thickness. remove plate (11) and boom foot pin (12). [*3]
4 Boom cylinder head pin:
60 kg
• Removal by using tool V

Remove plate (11) and remove boom foot pin
(12) by using tool V.
5. Start the engine and then retract the piston rod.
a Shims are installed, so note their quantity
a Cover the cylinder head on a stand with the and thickness.
piston rod tied by using wire to prevent it
from coming out, or support the cylinder
head with a block to prevent it from lowering.
When supporting it with a block etc., remove
the grease nipple at the cylinder bottom.
PC360LC-10 50-195
Work equipment
2 Inner surface of bushing when installing

4 Boom foot pin:
pin:
80 kg
Grease (LM-G)
your fingers in them.
a Adjust clearance (b) between cylinder rod (14)

and plate (4) to 1.5 mm or less by using shims.
a Install one shim or more on each end face.
a Shim thickness
• Shim (15): Adjust by combining 1.0 mm and
11.Remove work equipment assembly (13). 2.0 mm shims.
• Shim (16): 1.0 mm
4 Work equipment assembly: • Shim (17): 1.0 mm
6,200 kg • Shim (18): 1.0 mm
Installation (PC300-L410-720-K-00-A) [*3]

• Perform installation in the reverse order to 2 Inner surface of bushing when installing
removal. pin:
[*1] Molybdenum disulphide lubricant (LM-P)
a When tightening the lock nut, tighten so that 2 Pin after installed in position:
clearance (a) between the plate and nut is as
shown below. Grease (LM-G)
Clearance (a): 0.5 to 1.5 mm a Adjust clearance (c) between the foot end face
of boom (19) and bracket (20) to 1 mm or less by
using shims.
a Install one shim or more on each end face.
[*2]
50-196 PC360LC-10
Work equipment
a Shim thickness
• Shim (21): 2.0 mm
• Shim (22): Adjust by combining 2.0 mm, 2.5
mm, 3.0 mm or 3.5 mm shims.

again.
• Bleeding air
Bleed the air. For details, see Testing and
adjusting, "Bleeding air from hydraulic circuit."
PC360LC-10 50-197
Work equipment
Disassembly and assembly of work equipment cylinder (PC300-PPZ0-926-K-00-A)
a Special tools 2. Disassembly of piston rod assembly

1) Set piston rod assembly (2) on tool U1.
Necessity
Symbol
Q'ty
Part No. Part name
1 790-502-1003 Cylinder repair stand t 1

790–102– Wrench assembly t 1
4300
2
790–102–
Pin t 2
4310
790–720– Expander
3 q 1
1000
796–720– Ring q 1
4 1680
07281–01589 Clamp q 1
790–201– t 1 2) By using a hexagonal wrench (6 mm),
Push tool kit
1702
remove lock screw (3) at the end of piston
• Push tool (for boom
U 790-201-1851and bucket) 1 assembly (4).
5
790-201-1861 • Push tool (for arm) 1 a The above work is common to the boom,
790–101– arm, and bucket cylinders.
• Grip 1
5021 • Screw size: M12 x 1.75 mm (length: 16
01010–50816 • Bolt 2 mm)
790–201–
Push tool kit t 1
1500
• Plate (for boom and
790-201-1660 bucket) 1
6
790-201-1670 • Plate (For arm) 1
790–101– • Grip 1
5021
01010–50816 • Bolt 2
Disassembly (PC300-PPZ0-530-K-00-A)
1. Disconnection of cylinder assembly and piston

rod assembly
1) Remove the piping from the cylinder
assembly.
2) Remove the 12 mounting bolts to disconnect a If screw (3) is punched too firmly to be
cylinder head assembly (1). loosened, tighten the screw further in and
3) Pull out piston rod assembly (2). apply tap (T) on the threads to eliminate
punch mark.
a Place an oil pan etc. under the cylinder to
receive the oil in the cylinder.
3) By using tool U2, remove piston assembly

(4).
50-198 PC360LC-10
Work equipment
a When not using tool U2, use the drill 3) Remove piston ring (13).
holes (H)(f10: 2 places) to loosen the 4) Remove the O-ring and two backup rings
piston assembly. (14).
4) Remove plunger (5). 4. Disassembly of cylinder head assembly

a Perform this work only for boom and arm 1) Remove the O-ring and backup ring (15).
cylinders. 2) Remove snap ring (16), then remove dust
5) Remove collar (6). seal (17).
3) Remove rod packing (18) and buffer ring
a Perform this work only for boom and arm (19).
cylinders. 4) Remove snap ring (30).
6) Remove cylinder head assembly (7). 5) Remove bushing (20).
7) Remove cap (8), take out twelve balls (9),

and remove plunger (10). Assembly (PC300-PPZ0-710-K-00-A)
a Be careful not to damage the packings, dust

a Arm cylinder only
seals, O-rings, etc.
a Clean all the parts. After assembling the cylinder,
cover the piping ports and pin holes to prevent
dirt from entering.
a Do not install the backup ring forcibly, but warm
it in hot water of approximately 50 to 60 °C and
then install.
1. Assembly of cylinder head
1) By using tool U5, press fit bushing (20).
2) Install snap ring (30).
3) Install buffer ring (19) and rod packing (18).
4) By using tool U6, install dust seal (17) and
3. Disassembly of piston assembly secure it with snap ring (16).
5) Install backup ring (15) and O-ring.
1) Remove two rings (11).
2) Remove two wear rings (12).
PC360LC-10 50-199
Work equipment
3. Assembly of piston rod

1) Set piston rod assembly (2) to tool U1.
2. Assembly of piston
1) Set piston ring (13) on tool U3, and rotate the
handle eight to ten turns to expand piston 2) Install cylinder head assembly (7).
ring (13). 3) Fit the O-ring and backup ring to collar (6),
2) Remove piston ring (13) from tool U3 and and then install them to the piston rod.
install it to the piston.
3) By using tool U4, compress piston ring (13). a Install the two backup rings, one each in
the front and rear of the O-ring.
a Only the boom and arm cylinders
4) Install plunger (5).
a Only the boom and arm cylinders
4) Install two backup rings (14) and O-ring.

a Install the backup rings and O-ring in the
directions shown in the figure below.
5) Install two wear rings (12).
6) Install two rings (11). 5) Set plunger (10) to piston rod assembly (2),
a Be careful not to open the closed gap of and then install twelve balls (9) and cap (8).
the ring excessively. a After assembling, check that the plunger
2 Ring groove: end has a little play.
Grease (G2-LI)
50-200 PC360LC-10
Work equipment
a Arm cylinder only a If the cylinder has the head cushion,

check that plunger (5) has a little play
after installing piston assembly (4).
• Only the boom and arm cylinders
6) When reusing both of piston rod assembly

(2) and piston assembly (4), assemble them
in the following procedure. (When replacing
either or both of them with new ones, see 2] Install screw (3) to fix piston assembly (4)
step 7) and piston rod assembly (2).
1] By using tool U2, install piston assembly
2 Threaded portion of screw (3):
(4) to piston rod assembly (2).
Liquid adhesive (Loctite #262)
a Remove any burrs or sharp edges on
the threaded portion with a file before 3 Screw (3):
installing. 58.9 to 73.6 Nm {6 to 7.5 kgm}
a After installing screw (3), punch four
places (a) around the screw.
a Tighten piston assembly (4) to piston

rod end (b) and align screw holes (H)
of the piston and piston rod. 7) When replacing either or both of piston rod
assembly (2) and piston assembly (4) with
new ones, assemble them in the following
procedure.
1] By using tool U2, tighten piston rod
assembly (4) to end (b) of the rod.
a If the cylinder has the bottom cushion,
make a mark of the tightening position
of the ball cap on the rod end face.
3 Piston assembly (4):
294 ± 29.4 Nm {30 ± 3.0 kgm}
a If the cylinder has the head cushion,
check that plunger (5) has a little play
after installing piston assembly (4).
• Only the boom and arm cylinders
PC360LC-10 50-201
Work equipment
3 Screw (3):
58.9 to 73.6 Nm {6 to 7.5 kgm}
2] Make a screw hole for the lock screw to

the threaded portion between piston rod
assembly (2) and piston assembly (4).
4. Connection of cylinder assembly and piston rod
a Apply the drill to the V-groove of the assembly
threaded portion between piston
1) Set piston rod assembly (2) on tool U1.
assembly (4) and rod (2), and make a
hole horizontally.
a If the cylinder has the bottom cushion,
make the hole apart from the hole for
the cushion cap.
• Dimensions of screw hole (mm):
Tap drill diameter 10.3
Tap drill hole depth 27
Screw hole size 12 x 1.75
Screw hole depth 20
a After tapping, remove all the chips and

dirt and clean the parts.
2) Install the cylinder assembly to piston rod
assembly (2).
a Align axial center of the cylinder tube,
then insert.
a Check that the ring is not broken and has
not come out, then push in fully.
3] Install screw (3) to fix piston assembly (4)

and piston rod assembly (2).
a After installing screw (3), punch four
places (a) around screw (3).
2 Threaded portion of screw (3):
Liquid adhesive (Loctite #262)
3) Tighten the mounting bolts of cylinder head
assembly (1).
50-202 PC360LC-10
Work equipment
3 Mounting bolt of cylinder head

assembly (1):
Boom cylinder: 373 ± 54 Nm {38.0
± 5.5 kgm}
Arm cylinder: 530 ± 78.5 Nm {54.0
± 8.0 kgm}
Bucket cylinder: 373 ± 54 Nm {38.0
± 5.5 kgm}
4) Install the piping.

3 Mounting bolt of piping fixing band
Boom: 32.3 ± 6.9 Nm {3.3 ± 0.7
kgm}
Arm: 54 to 123 Nm {5.5 to 12.5
kgm}
Bucket: 98 to 123 Nm {10.0 to 12.5
kgm}
PC360LC-10 50-203
Removal and installation of operator's cab assembly (PC220-K000-924-K-00-A)
a Remove harness (4) by passing it through

the space between cover (5) and duct (6).
stop the engine.


before disconnecting wiring and hoses.
a Positions of the controllers are shown below.
• A: Pump controller assembly
• B: Air conditioner controller assembly
• C: KOMTRAX terminal
5. Remove box (9) (five bolts).

Removal (PC300-K000-520-K-00-A) a Disconnect the hose located under box (9).
1. Remove the machine monitor assembly. For 6. Remove box (10) (three bolts).
details, see "Removal and installation of a Be careful about connectors (11) and (12)
machine monitor assembly". located behind box (10) (for machines
2. Remove the floor mat. equipped with 12 V power socket).
3. Remove cover (1) first, and then remove cover • Connector (11): 12 V power socket
(2). intermediate harness (M13A)
4. Remove cover and duct assembly (3). • Connector (12): 12 V power socket
intermediate harness (M13B)
7. Remove cover (13) (three bolts).
50-204 PC360LC-10
a Disconnect connectors (18) and (19) located

behind cover (17).
• Connector (18): R.H. console
intermediate harness (H14)
• Connector (19): R.H. console
intermediate harness (H15)
8. Remove cover (14) (seven bolts).

a Disconnect connector (15) located behind
cover (14).
• Connector (15): Cigarette lighter (M04)
9. Remove duct (16).

11.Remove plate (20).
12.Pull up lock pin (21) to unlock and remove duct
(22).
13.Remove ducts (23) and (24).

• Connector (25): Room lamp (L03)
PC360LC-10 50-205
a Cut the cable ties holding the ducts and • Connector (33): AUX intermediate connector
connectors. (M01B)
• Connector (34): Operator's cab roof
intermediate connector (H09)
• Connector (35): Loudspeaker intermediate
connector (H08)
a Neatly arrange and place the disconnected
connector on the floor apart from the
operator's cab.
18.Disconnect radio antenna (36).
a Cut the cable ties holding the antenna.
radio antenna parts on the floor apart from
15.Disconnect connectors (26) to (29) from the operator's cab.
KOMTRAX terminal (C).
• Connector (26): Communication antenna
(GPS)
• Connector (27): Machine main harness
(CK01).
(CK02).
operator's cab.
19.Remove four bolts (37) and remove pump

controller assembly (A). Neatly arrange and
place the assembly on the floor apart from the
operator's cab.
16.Remove connector (30) from the clip at the

operator's cab.
• Connector (30): L.H. console intermediate
harness (H16)
connector on the floor apart from the 20.Disconnect connectors (38) to (40) from air
operator's cab. conditioner controller assembly (B).
17.Release connectors (31) to (35) from the clips at • Connector (38): Air conditioner compressor
the operator's cab and disconnect the electromagnetic clutch relay (R21)
connectors. • Connector (39): Machine main harness
• Connector (31): 12 V power socket (AC02)
intermediate harness (M10) (for machines • Connector (40): Machine main harness
equipped 12 V power socket) (AC01)
• Connector (32): Handsfree microphone a Air conditioner controller assembly (B) can
intermediate harness (M46) (for machines be easily removed after the above
equipped handsfree microphone) connectors are disconnected.
50-206 PC360LC-10

operator's cab.
21.Remove two bolts (41) and remove air
conditioner controller assembly (B). Neatly
arrange and place the assembly on the floor
apart from the operator's cab.
26.Disconnect window washer hose (50).

27.Cut cable ties (52) holding window washer hose
(50) and harness (51).
a Arrange them neatly and place window
washer hose (50) and harness (51) on the
floor.
22.Remove ducts (42) and (43).

a Cut the cable ties holding the ducts.
• Connector (44): Front window wiper motor
(M05)
28.Remove bolt (53) from under the rear left side of

the operator's cab, and then remove lock plate
(54).[*1]
29.Remove cab tipping stopper (55) (width across
flats: 46 mm).[*2]
24.Remove ducts (45) to (47).
30.Remove cover (58) from the rear of the

operator's cab.
25.Remove clamp (49).
PC360LC-10 50-207
31.Remove brackets (59). 34.Sling and remove operator's cab assembly (61).
32.Remove cover (60) from the side of the
a Lift up the operator's cab little by little while
hydraulic tank.
checking that every hose, connector, and
clamp is disconnected.
4 Operator's cab assembly (61):

470 kg

removal.
[*1]
3 Lock plate mounting bolt (53):
98 to 123 Nm {10.0 to 12.5 kgm}
33.Remove operator's cab mounting bolts (56) and [*2]
nuts (57).[*3] 3 Cab tipping stopper (55):
a Bolt (56): 6 places 245 to 309 Nm {25.0 to 31.5 kgm}
a Nut (57): 4 places [*3]
3 Operator's cab mounting bolt (56):
98.1 to 122.6 Nm {10 to 12.5 kgm}
50-208 PC360LC-10
Removal and installation of operator cab glass (adhered glass) (PC220-K183-924-

K-00-A)
a Special tools
Necessity
Sym-
Q'ty
Part No. Part Name
bol
2 793-498-1210 Lifter (suction cup) t 2

X
3 20Y-54-13180 Stopper rubber t 2
a Although some of the figures depict another

model, the replacement procedure is basically
the same.
a Among the glass panels on the four sides of the
operator's cab, five panes (1) to (4) and (18) are
adhered.
a In this section, the procedures for replacing the
adhered glass are explained.
a When replacing front window glass (4), remove
front window assembly (5). (It is impossible to
replace only the front window glass while the
front window assembly is installed to the
operator's cab.)
a For the procedure for replacing the front window
assembly, see "Removal and installation of front
window assembly".
PC360LC-10 50-209
(1): Right side window glass

(2): Left side rear window glass
(3): Door lower window glass
(4): Front window glass
(5): Front window assembly (front window glass and front frame)
(6): Dam rubber
(17): Center trim seal
(18): Rear window glass
50-210 PC360LC-10
Removal (PC220-K183-520-K-00-A)
a Remove the window glass to be replaced

1. Using seal cutter [1], cut the adhesive between
broken window glass (7) and operator's cab
(metal sheet) (8).
a If the window glass is broken into small

pieces, they may be removed with knife [4]
and a flat-head screwdriver.
a Widening the cut with a flat-head screwdriver,
cut the adhesive and dam rubber with knife
[4].
2. Remove the window glass.
PC360LC-10 50-211
1. Using a knife and scraper [5], remove the a Use the primer within two hours after opening
remaining adhesive and dam rubber from the container.
sheet metal (adhesion surfaces) of the
a Even if the container of the primer is capped
operator's cab.
again just after it is opened, use it out within
a Remove the adhesive and dam rubber to a 24 hours after it is opened for the first time.
degree that they will not affect adhesion of (Discard the primer which is left unused 24
the new adhesive. Take care not to scratch hours after it is opened.)
the painted surfaces. (If the painted surfaces 1) Stir the primers for painted surface and glass
are damaged, adhesion will be lowered.) sufficiently before using them.
(The figure shows the operator's cab of a wheel
loader.) a If the primer is stored in a refrigerator,
leave it at the room temperature for at
least half a day before stirring it. (If the
primer is opened just after taken out of
the refrigerator, water will be condensed.
Accordingly, leave the primer at the room
temperature for a sufficient time.)
2) When reusing primer brush (11), wash it in
white gasoline.
a After washing the brush, check it again
for dirt and contaminants.
a Prepare respective brushes for the
painted surface primer and glass primer.
2. Remove oil, dust, dirt, etc. from the adhesion
surfaces on cab (8) and window glass (9) with
white gasoline.
a If the adhesion surfaces are not cleaned well,
the window glass may not be bonded
perfectly.
a Clean all the black part on the back of the
window glass.
a After cleaning the adhesion surfaces, leave
them for at least 5 minutes to dry.
(The figure shows the operator's cab of a wheel
loader.) 3) Evenly apply the painted surface primer to
the surfaces on operator's cab (8); the
surface where dam rubber (6) is bonded on
and its outside surfaces where the adhesive
is applied to.
2 Primer for painted surface:
Sunstar Primer 580 Super for
painted surfaces
a Do not apply the primer more than two
times. (Applying primer more than twice
will degrade the performance.)
3. Apply primer (10).

a The primer is good for four months after the
date of manufacture. Do not use the primer
after the expiration date.
50-212 PC360LC-10
a Places to apply: Apply over the entire a Never apply wrong primer. If the paint
circumference with dimension (a). primer is applied by mistake, wipe it off
• Primer applying dimension (a): 30 mm with white gasoline. If glass primer, etc. is
applied by mistake, wipe it off with white
gasoline.
4) Evenly apply the glass primer to the
adhesion surfaces of glass (9).
2 Primer for glass:
Sunstar Primer 453-41 for glass
a Do not apply the primer more than two
times. (Applying primer more than twice
will degrade the performance.)
a In addition to the above places, apply

primer to right side window glass (1) and
lower door glass (3).
• Area to apply additional primer for right
side window glass (1): (b)
• Area to apply additional primer for lower
door window glass (3): (c)
a After applying the primer, leave it in air for
at least five minutes (maximum eight
hours) to dry. a Places to apply: Apply the primer to
adhesion surface (d) on window glass (9)
along its circumference, which is
determined by the installed position of
dam rubber (6) and operator's cab (8).
• Primer applying dimension (d): 30 mm
a Do not apply the primer to the boarder
area of about 5 mm wide between the
black portion and transparent portion of
the glass.
a After applying the primer, leave it in air for
at least 5 minutes (maximum 8 hours) to
dry.
a Never apply wrong primer. If painted
surface primer is applied by mistake,
wipe it off with white gasoline.
PC360LC-10 50-213
a Stick additional dam rubber (6a) for right

side window glass (1).
• Positions to stick additional dam rubber
for right side window glass:
(f): 50 mm
(g): 90 mm
(h): 250 mm
4. Stick dam rubber (double-sided tape) (6) to the

operator's cab as follows.
a Do not remove the release tape of dam
rubber on the glass sticking side before
sticking the window glass.
a When sticking the dam rubber, do not touch
the cleaned surface. 2) Stick dam rubber (6) for left side rear window
a Care should be taken not to slacken the dam glass (2) to the position as shown in the
rubber of each sticking corner. figure.
3) Stick dam rubber (6) for door lower window

a When sticking dam rubber (6) all around, do glass (3) to the position as shown in the
not overlap the ends. Or, provide a clearance figure.
of approximately 5 mm between ends (e).
1) Stick dam rubber (6) for right side window
glass (1) to the position as shown in the
figure.
a Stick additional dam rubber (6b) for door

lower window glass (3).
• Positions to stick additional dam rubber
for door lower window glass:
(j): 110 mm
50-214 PC360LC-10
(k): 90 mm a For accurate positioning, stick tape [6]

(m): 200 mm across the left, right, and bottom edges of
the right side window glass, left side rear
window glass, and door lower window
glass.
3) Cut the tape between window glass (9) and
operator's cab (8) with a knife, etc. and then
remove the window glass.
a Do not remove the tapes left on the
window glass and operator's cab (8)
before installing the window glass.
4) Stick dam rubber (6) for front window glass

(4) to the position shown in the figure.
a Stick lower dam rubber (6c) for the front

window glass along the outside edge of
the lower frame, differently from other
dam rubbers (6). (If it is stuck along the
inside, it will be seen through the
transparent portion of the glass.)
a When positioning front glass (4),

• set right and left installing positions to
the frame width.
• set its vertical position to make the
height difference (p) between the
frame top and the front window glass
(4) 3 mm.
5. Position the new window glass.

1) Check the clearances between the window
glass and the operator's cab on the right, left,
upper, and lower sides, and then position the
window glass so that it is centered.
2) Stick tapes [6] between window glass (9) and
operator's cab (8). Draw a positioning line (n)
on each tape.
PC360LC-10 50-215
6. Apply adhesive.
a Use either of the two types of adhesives
according to the season.
2 Adhesive (summer):
Sunstar penguine seal 580 super "S"
or equivalent
2 Adhesive (winter):
Sunstar penguine seal 580 super "W"
or equivalent
a The using limit of the adhesive is four months
after the date of manufacture. Do not use the 4) Remove the release tape from dam rubber
adhesive after the period. (6) on the glass sticking side.
5) Apply adhesive (15) to the outside of dam
a Keep the adhesive in a dark place where the
rubber (6) on the operator's cab.
temperature is below 25°C.
a Never heat the adhesive higher than 30°C.
a When reusing the adhesive, remove all the
hardened part from the nozzle tip.
1) Remove aluminum seal (13) of the outlet of
adhesive cartridge (12) and install the
nozzle.
a Adjacent to dam rubber (6) on operator's cab

(8), apply adhesive (15) in dimensions (s)
and (t) as shown in the figure.
• Dimension (s): 10 mm
• Dimension (t): 15 mm
a Apply adhesive (15) thicker than dam rubber
2) Cut the tip of the adhesive nozzle (14) so that (6).
dimensions (q) and (r) are as follows. a Apply the adhesive evenly in height.
• Dimension (q): 10 mm
• Dimension (r): 15 mm
a Apply adhesive (15) adjacent to additional

3) Set adhesive cartridge (12) to caulking gun dam rubber (6a) for right side window glass
[7]. and additional dam rubber (6b) for lower door
window glass.
a An electric caulking gun is more efficient.
50-216 PC360LC-10
a After installing front window glass (4) fill

the clearances between the window glass
and center trim seal (16) with caulking
material in range (s) with dimensions (t)
and (u).
a After applying the primer to the part of
window glass (4) shown in section A-A,
apply the adhesive as caulking material.
• Caulking dimension (t): 2 mm
• Caulking dimension (u): 5 mm
a When caulking, apply masking to the
7. Install the window glass. window glass and form the adhesive with
1) Install window glass (9) while aligning the a rubber spatula as shown in the figure.
lines drawn on the positioning tapes in step a Wipe off the squeezed adhesive.
5.
2 Primer for glass:
a Since the window glass cannot be
Sunstar Primer 580 Super for
removed and installed again, install it with
glass
utmost caution.
2 Adhesive:
a Install the window glass within 5 minutes
after applying the adhesive. Sikaflex 250-2
2) After installing window glass (9), press entire
circumferential area until it adheres firmly to
the dam rubber.
a Press the corners of the window glass
firmly.
a You can perform this work efficiently by

pulling window glass (9) from inside of the
operator's cab using suction cup X2.
PC360LC-10 50-217
2) Using styrene foam blocks [9] and rubber

bands [10], fix the window glass to the dam
rubber to bond them completely.
9. After installing the window glass, remove any

excess of the primer and adhesive on the
operator's cab and window glass.
a Use white gasoline to wipe off the remaining
adhesive before it dries up.
a When cleaning the glass, do not give an
impact to it.
10.Cure the stuck window glass.
1) Keep the stopper rubbers, styrene foam
8. Fix the glass. blocks, and rubber bands installed for ten
hours as a curing period. (at temperature of
1) After installing right side window glass (1) to 20℃ and humidity of 60%)
the operator's cab, install stopper rubbers X3 2) After removing the stopper rubbers, styrene
to 2 places (v) at the bottom of the window foam blocks, and rubber bands, wait at least
glass to fix it. fourteen hours, at least twenty four hours in
total, before operating the machine actually.
50-218 PC360LC-10
Removal and installation of front window assembly (PC220-K181-924-K-00-A)

the engine.
k Removal and installation must be done by a

pair of two workers.
a To replace the front window glass, the front

window assembly must be removed from the
operator's cab.
Removal (PC220-K181-520-K-00-A)
1. Pull up front window assembly (1) to the ceiling

and lock it. 4. Release the lock of front window asembly (1).
a Make sure that the assembly is certainly

locked.
2. Remove front lower window (2).
3. Remove bracket (3) at the left corner (two

screws) and bracket (4) at the right corner (two
screws). [*1]
a Leave mounting screws (5) and washers (6)
for bracket (3) at the left corner in position.
They are used to hook the pull-up assist
cable in Step 6.
5. Carefully slide front window assembly (1) down

until the lower part of front window assembly (1)
is detached from the operator's cab through the
ends from which the corner brackets are
removed in Step 2 (rail missing ends) and
support the lower part of the front window
assembly.
a Right and left rollers (8) and (7) are insertion-
fitted, so they easily become detached.
Handle them carefully.
PC360LC-10 50-219
7. Lower front window assembly (1) completely.

a Take care not to let front window assembly
(1) touch machine monitor (12).
6. Remove pin (9). [*2]

a Removal of pin (9) allows plate (11) at the
end of pull-up assist cable (10) to come off.
a Hook plate (11) on screw (5) of left corner 8. Carefully slide front window assembly (1) down
bracket (3) to hold the plate (used washer (6) to detach the top of the front window assembly
as well). from the operator's cab through the ends from
which the left and right corner brackets are
removed in Step 2 (rail missing ends).
k Pull-up assist cable (10) is under a return
load of 58.8 N {6 kg} that is working a Right and left rollers (14) and (13) are
toward the rear of the operator's cab. So insertion-fitted, so they easily become
be fully careful when removing pin (9) detached. Handle them carefully.
during the disconnection of the cable.

removal.
[*1]
50-220 PC360LC-10
• Adjust opening and closing of front window

assembly (1) according to the following
procedure.
1. Open and close front window assembly (1) to
check that it does not interfere with the rails and
that the rollers are not caught.
2. If there is any problem in opening or closing of
front window assembly (1), loosen mounting
bolts (16) of roller adjustment bracket (15) and
adjust the condition of the front window, and
then tighten the mounting bolts again.
a Make sure that bracket (15) is not slanted
when mounted.
3 Mounting bolt (16) of bracket (15):
19.6 to 25.0 Nm {2.0 to 2.5 kgm}
5. Install left corner bracket (3).

a Tighten lightly for the meantime. Bolts are
tightened to the specified torque after
adjusting the locks for the front window
3. Pull up front window assembly (1) to the ceiling assembly (1) in its "closed" position in the
and lock it. following step 6.
a Make sure that the assembly is certainly a Install left corner bracket (3) so that
locked. clearance (b) between rail (18) and left
4. Install right corner bracket (4). corner bracket (3) becomes 0 to 2.0 mm.
a Tighten lightly for the meantime. Bolts are a There must be no level difference on rolling
tightened to the specified torque after surface (R) for the roller (same as the right
adjusting the locks for the front window corner bracket).
assembly (1) in its "closed" position in the
following step 6.
a Install right corner bracket (4) so that
clearance (a) between rail (17) and right
corner bracket (4) becomes 0 to 2.0 mm.
a There must be no level difference on rolling
surface (R) for the roller.
6. Adjust the locks for the front window assembly

(1) in its "closed" position according to the
1) Install right and left corner brackets (4) and
(3) in roughly right positions so that front
PC360LC-10 50-221
window glass (19) is closely attached to cab-

side trim seal (20).
7. After the adjustment, splash water heavily over

the front window glass and check that the water
does not leak into the cab.
2) Check the working condition of right and left
8. Adjust the locks for front window assembly (1) in
locks (22) and (21) when opening and
its "open" position.
closing front window assembly (1).
1) After adjusting the locks for the front window
a If right and left locks (22) and (21) rattle; assembly (1) in its "closed" position in steps
1] Loosen lock fixing bolt (23) inside the 6 and 7, pull up front window assembly (1) to
cover, move lock (21) forward, and then the ceiling.
tighten the bolt again. (The same applies 2) Check the locks at the rear right and left of
to the right side.) the operator's cab on the following items with
2] After moving the lock, check the contact front window assembly (1) in its "open"
between front window glass (19) and cab- position.
side trim seal (20) which was checked in • Check the working condition of right and
step 1). left locks (22) and (21) (as explained
3] Repeat the work in 1] and 2] until the above).
contact of front window glass (19) and the • Front window assembly (1) must be in
working condition of right and left locks contact with the right and left rubber
(22) and (21) are both acceptable, and stoppers (24), and furthermore, must be
then tighten the mounting bolts of the pushing them backward by 1.5 to 3.0
right and left corner brackets (tighten to mm.
the specified torque). • Check that limit switch (25) is pushed
back 4 to 7 mm by front window assembly
(1).
a Since the position of limit switch (25)
cannot be adjusted, the "open" position of
front window assembly (1) is decided
within the functioning range of this switch.
a Limit switch (25) prohibits wiper operation
if the wiper switch is turned ON by
mistake while the front window assembly
is "open".
a The wiper falls into the operator's cab and
breaks if operated when front window
assembly (1) is open.
a To check whether limit switch (25) is
working, turn the starting switch to ON
position and see that, even if the wiper
switch is turned on, the wiper does not
operate when front window assembly (1)
is in the "open" position.
50-222 PC360LC-10
• When adjustment is needed after 6) Adjustment of right and left rubber stoppers
performing check in step 8; (24)
3) Close front window assembly (1). • Bring right and left rubber stoppers (24)
4) Loosen locknuts (26) of right and left rubber into contact with front window assembly
stoppers (24) and move the stoppers (1) (locked in "open" position).
backward so that front window assembly (1)
does not touch the stoppers when it is locked
in its "open" position.
• Close front window assembly (1).

• Turn right and left rubber stoppers (24) to
the left one and a half rotation.
5) Loosen lock nut (27) at both sides, and
adjust the position of striker bolt (28). a One turn of rubber stopper (24) to the left
is equivalent to squashing the rubber by
• Striker bolt (28): M10
approximately 1.5 mm.
• Diameter of hole in plate (29): 14.5 mm
a When front window assembly (1) is
locked in "open" position, front window
assembly (1) must be pushing right and
left rubber stoppers (24) by 1.5 to 3.0
mm.
• Front window assembly (1) (locked in

"open" position) must be pushing the limit
switch (25) backward by 4 to 7 mm.
• Working condition of lock (31).
• Tighten lock nuts (26) of right and left

rubber stoppers (24).
PC360LC-10 50-223
9. Adjust anti-vibration stoppers (30) of front

a Also check the latching efforts of right and
window assembly (1).
left locks (33) and (34) for the front window
1) Adjust and lock anti-vibration stopper (30) at assembly in its "closed" position (at front side
both sides so that surface (d) of stopper (D) of the operator's cab).
is in contact with surface (c) of anti-vibration
stopper (30) when front window assembly (1)
is pulled up.
[*2]
3 Pin (9):
27 to 34 Nm {2.8 to 3.5 kgm}
2 Thread portion of pin (9):
Adhesive (LT-2)
10.Check the latching efforts of front window

assembly (1).
a After finishing the adjustment of steps 6 to 9,
check that latching efforts of both right and
left locks (32) and (31) are even.
50-224 PC360LC-10
Removal and installation of floor frame assembly (PC220-H1H0-924-K-00-A)
k Park the machine on a level ground, lower a Refrigerant to be collected:

the work equipment to the ground, and stop 750 ± 50 g
the engine. 3. Remove undercover (2).


k If you drain the coolant or disconnect the

heater hose when the radiator coolant
temperature is high, you may be scalded. In
such case, wait until the coolant temperature
lowers and then drain the coolant or 4. Loosen drain valve (3) at the bottom of the
disconnect the heater hose. radiator to drain the coolant. (Drain hose: inside
diameter f7 mm)
your skins, you may suffer from frostbite. 6 Radiator:
Accordingly, put on the protective 37 l
filling refrigerant (R134a).
a Never release the refrigerant (R134a) to the

atmosphere.
a Fit a plug or flange to the disconnected hydraulic
hose ends to prevent oil from flowing out. 5. Remove undercover (4) under the operator's
Removal (PC300-H1H0-520-K-00-A) cab.
1. Remove operator's cab assembly (1), referring
to "Removal and installation of operator's cab
assembly".
6. Disconnect ground cables (5).

PC360LC-10 50-225
a The hose bands are colored as follows:

• Hose (18): Black (port (P1))
• Hose (19): Brown (port (P2))
7. Disconnect connectors (7) to (10) from travel

PPC valve (6).
• Connector (7): L.H. travel reverse oil
pressure sensor (P10) 11.Disconnect connectors (21) and (22) from 1-way
• Connector (8): L.H. travel forward oil attachment PPC valve (20). (for machines
pressure sensor (P09) equipped with attachment)
• Connector (9): R.H. travel forward oil • Connector (21): Pedal rear inclination oil
pressure sensor (P11) pressure switch (P14)
• Connector (10): R.H. travel reverse oil • Connector (22): Pedal front inclination oil
pressure sensor (P12) pressure switch (P15)
8. Disconnect hoses (11) to (14) from travel PPC 12.Disconnect hoses (23) and (24) from 1-way
valve (6). attachment PPC valve (20). (for machines
a The hose bands are colored as follows: equipped with attachment)
• Hose (11): Red (L.H. travel forward port a The hose bands are colored as follows:
(P2)) • Hose (23): Yellow (port (P1))
• Hose (12): Without band (L.H. travel • Hose (24): Without band (port (P2))
reverse port (P1)) 13.Disconnect connectors (25) and (26). (for
• Hose (13): Blue (R.H. travel reverse port machines equipped with attachment)
(P3)) • Connector (25): Attachment oil flow rate
• Hose (14): Green (R.H. travel forward adjuster EPC valve (V30)
port (P4)) • Connector (26): Intermediate connector
(P13) of attachment oil pressure switch
a Cut all cable ties that hold the harnesses to
the floor frame.
9. Disconnect connectors (16) and (17) from 2-way

attachment PPC valve (15). (for machines
equipped with attachment)
• Connector (16): Pedal front inclination oil
14.Disconnect clamps (27) (two bolts).
pressure switch (P16)
• Connector (17): Pedal rear inclination oil
pressure switch (P30)
10.Disconnect hoses (18) and (19) from 2-way
attachment PPC valve (15). (for machines
50-226 PC360LC-10
a Disconnect work equipment PPC valve

hoses (P) from the relay block. (See Step
34.)
15.Disconnect ground cables (28).

a Ground cable arrangement (from left to right):
(T04), (T05), (T06), (T07), (T09), (T10)
16.Remove clamps (29) and (30). 19.Disconnect hose (35).
• Hose (35): Port (T) (drain circuit to the
hydraulic tank)
• Connector (36): Dual pressure switch (P17)
of air conditioner
a Cut all cable ties that hold the harnesses to
the floor frame.
21.Remove bolt (37), then disconnect tubes (38) of
the air conditioner. [*2]
22.Remove clamp (39) (one bolt) fastening tubes
(38).
23.Disconnect heater core hoses (40). [*3]
17.Pull connectors (31) to (33) out of the clips. 24.Remove clamp (41) (one bolt) (with a spacer)
• Connector (31): Intermediate connector fastening hoses (40).
(A41) (for machines equipped with a 2nd
camera)
• Connector (32): Intermediate connector
(A42) (for machines equipped with a 3rd
camera)
• Connector (33): Intermediate connector
(A08) (for machines equipped with
attachment)
18.Disconnect hose (34).
• Hose (34): Port (P) (circuit from PPC
hydraulic lock solenoid valve)
25.Remove clamps (42) and (43) (two bolts each).

26.Cut cable tie (44).
27.Remove clamp (45) (one bolt). (for machines
PC360LC-10 50-227
28.Disconnect connector (46) and remove air 30.Disconnect ground cable (T01) (50).
conditioner controller (B) from the main harness. 31.Disconnect all clamps that fasten main harness
• Connector (46): Machine main harness (51) to the floor frame.
(AC04) a Separate the pump controller assembly and
main harness from the floor frame and move
them toward the boom.

• Connector (47): R.H. console intermediate
harness (H14) 32.Open the engine hood and remove cover (52).
harness (H15)
• Connector (49): L.H. console intermediate
harness (H16)

a Move the hoses toward the control valve to
allow disconnecting the work equipment
PPC valve hoses from the relay block.
a Cut the cable ties holding the hoses.
50-228 PC360LC-10
a Lift up the operator's cab little by little while

checking that every hose, connector, and
clamp is disconnected.
4 Floor frame assembly (66):

250 kg
35.Disconnect hoses (57) to (64) from junction

block (56).
a Be sure to place a container to receive
hydraulic oil before disconnecting the hoses.
a The hose bands are colored as follows:
• Hose (57): White (bucket CURL circuit)
Reference: Precautions for removing work
• Hose (58): Brown (boom LOWER circuit)
equipment lever
• Hose (59): Without band (swing RIGHT
circuit) Using a flat-head screwdriver and the like, push lock
• Hose (60): Blue (arm IN circuit) (69) of resin frame (68) in boot (67) to remove boot
• Hose (61): Black (bucket DUMP circuit) (67) from console resin cover (70).
• Hose (62): Green (boom RAISE circuit) a Do not forcibly pull out any parts other than lock
• Hose (63): Red (swing LEFT circuit) (69) of resin frame (68) when performing this
• Hose (64): Yellow (arm OUT circuit) operation. Doing so may damage the resin
36.Pull out disconnected work equipment PPC frame.
hose assembly (65).
37.Sling and remove floor frame assembly (66).
PC360LC-10 50-229
a When installing the hoses of heater core, make

Installation (PC300-H1H0-720-K-00-A)
white line (marking) of heater hoses straight to
• Perform installation in the reverse order to prevent kink of heater hoses.
removal. • Refilling of oil (Hydraulic tank)
[*1] Add hydraulic oil through the oil filler port to the
• Filling air conditioner circuit with refrigerant specified level. Run the engine to circulate the
(R134a) oil through the piping. Then, check the oil level
Fill the air conditioner circuit with refrigerant again.
(R134a). • Bleeding air
a Filling quantity:
750 ± 50 g hydraulic system".
• Refilling of air compressor oil Reference: Precautions for installing cab mount
• Refilling of coolant (radiator) a The type of damper differs by the installed
Add coolant through the coolant filler to the position. Note the identification labels before
specified level. Run the engine to circulate the removing them. (See Structure and Function,
coolant through the system. Then, check the "Cab mount and cap tipping stopper.")
coolant level again. a Cab mounts must be installed with the mount
rubber groove (1) oriented as shown in the figure.
5 Radiator (coolant): (Top view. Left side of figure is the front side of
37 l (For details, see "Table of fuel, machine)
coolant and lubricants")
[*2]
a Check that there is no defect or deterioration on
the O-ring.

8 to 12 Nm {0.8 to 1.2 kgm}
[*3]
50-230 PC360LC-10
Removal and installation of air conditioner unit assembly (PC220-K500-924-K-00-A)

6 Radiator:
work equipment to the ground stably, and 37 l
stop the engine. 3. Pull up front window assembly (1) to the ceiling
and lock it.
k Turn the battery disconnect switch to the a Check that the front window is securely
OFF position and remove the key. locked.
k If you drain the coolant or disconnect the 5. Remove floor mat (3).
heater hose when the coolant temperature is
high, you may be scalded. In this case, wait
until the coolant temperature lowers and
then drain the coolant or disconnect the
heater hose.

your skins, you may suffer from frostbite.
Accordingly, put on the protective
filling the refrigerant (R134a).
a Never release the refrigerant (R134a) to the 6. Remove box (8) (five bolts).
atmosphere. a Disconnect the hose located under box (8).
a Ask a qualified person for collecting, adding, and 7. Remove box (9) (three bolts).
filling operations of the refrigerant (R134a). a Be careful about connectors (10) and (11)
a Note connector numbers and installed positions located behind box (9) (for machines
before disconnecting wiring and hoses. equipped with 12 V power socket).
• Connector (10): 12 V power socket
a Positions of the controllers are shown below. intermediate harness (M13A)
• A: Pump controller assembly • Connector (11): 12 V power socket
• B: Air conditioner controller assembly intermediate harness (M13B)
• C: KOMTRAX terminal controller assembly 8. Pull up cover (12) (three bolts) to remove.
a The connectors and wiring harnesses at the
rear must not be caught.
Removal (PC300-K500-520-K-00-A)

a Refrigerant to be collected: 750 ± 50 g
2. Drain coolant from bottom of the radiator.
(Drain hose: inside diameter f7 mm)
PC360LC-10 50-231
9. Remove cover (13) (seven bolts). 12.Remove plate (19) (two bolts).
13.Pull up lock pin (20) to unlock and remove duct
a Disconnect connector (14) located behind
(21).
cover (13).
14.Remove ducts (24) to (28). [*2]
10.Remove duct (15) (two bolts). a Cut the cable ties holding the ducts.
11.Remove cover (16) (three bolts) and bracket
(41) (two bolts).
a Disconnect connectors (17) and (18) located
behind cover (16).
harness (H14)
harness (H15)
15.Remove cable tie (39) of the left console wiring

harness.
50-232 PC360LC-10
16.Remove cable tie (40) of the floor wiring 19.Disconnect connectors (42) to (45).
harness. • Connector (42): Communication antenna
(GPS)
(CK01).
(CK02).
20.Remove KOMTRAX terminal (C) (four bolts).
17.Remove four bolts (29) and remove pump

controller assembly (A). Arrange the assembly
neatly and place it on the floor apart from the
operator’s cab.
21.Remove undercover (33).
18.Disconnect connectors (30) to (32) from air

conditioner controller assembly (B).
(AC01)
• Connector (31): Machine main harness 22.Remove bolt (34), then disconnect tubes (35) of
(AC02) the air conditioner. [*3]
• Connector (32): Air conditioner unit harness 23.Disconnect heater core hoses (36). [*4]
(AC04)
PC360LC-10 50-233
a Since the mounting bolts of cover (48) are

hidden by cover (47), remove cover (47) first.
24.Remove six mounting bolts (37) and remove air

conditioner unit assembly (38).
[*3]
Installation (PC300-K500-720-K-00-A) a Check that there is no defect or deterioration on
the O-ring.
removal. a Apply compressor oil (Denso: ND-OIL8) for
[*1] R134a refrigerant to O-rings.
• Filling air conditioner circuit with refrigerant
(R134a)
Fill the air conditioner circuit with refrigerant
(R134a).
a Filling quantity: 750 ± 50 g
• Refilling of coolant (radiator)
Add coolant through the coolant filler to the
coolant through the system. Then, check the
coolant level again.
5 Radiator (coolant): 3 Hose clamp (M6 bolt):

37 l (For details, see "Table of fuel, 8 to 12 Nm {0.8 to 1.2 kgm}
coolant and lubricants") [*4]
[*2]
a When installing the hoses of heater core, make
Removing cover (48) makes easier to install ducts white line (marking) of heater hoses straight to
(24) and (26). prevent kink of heater hoses.
50-234 PC360LC-10
Removal and installation of operator's seat (PC220-K2Q0-924-K-00-A)

stop the engine.

k Removal and installation work must be done

by a pair of two workers.

3. Pull lever (1) again and move operator's seat (2)

Removal (PC220-K2Q0-520-K-00-A) forward and fold the backrest forward.
1. Pull lever (1) and move operator's seat (2) 4. Remove two bolts (5) (with hexagonal socket)
backward. and two reinforcing plates (7), on the seat rail at
the rear side of operator's seat. [*1]
5. Disconnect connector (6) of the operator's seat.
• Connector (6): Seat belt caution switch (S19)
2. Remove two bolts (3) (with hexagonal socket)

and two reinforcing plates (4), on the seat rail at
the front side of operator's seat. [*1]
a For the heated seat

Remove wiring harness fixing band (8) and
disconnect connector (9).
(Connector (9) is located under the seat rail
mounting frame.)
• Connector (9): Heated sheet (M35)
PC360LC-10 50-235
4. Slide adjusters (11) and (12) backward and

forward approximately three times to make sure
that they slide smoothly.
5. Make sure that they are locked at the midpoint of
the sliding move, then tighten four bolts (13).
49 Nm {5.0 kgm}
6. Slide the seat assembly backward and forward
approximately three times. After making sure
that they are locked in the rearmost position,
tighten two bolts (15) of the front side.
6. Remove the operator's seat. 3 Mounting bolt (15) (front side):

49 Nm {5.0 kgm}
4 Operator's seat: 7. Slide the seat assembly backward and forward
21 kg approximately three times again. After making
sure that they are locked in the rearmost position,
Installation (PC220-K2Q0-720-K-00-A) tighten two bolts (15) of the rear side.
• Perform installation in the reverse order to 3 Mounting bolt (15) (rear side):
removal.
49 Nm {5.0 kgm}
[*1]
8. If a large operating effort is required (target is
3 Mounting bolts (3) and (5) of operator's max.15 kg), repeat adjustment and make sure
seat (hexagonal socket head): right and left locks work properly at respective
25.5 Nm {2.6 kgm} positions.
Reference: Assembly and adjustment procedure

for operator’s seat adjuster
1. Using four bolts (13), install adjusters (11) and
(12) loosely to frame (10). At the same time,
install two wires (14) for releasing slide lock.
a Check that right and left locks work properly.
2. Slide adjusters (11) and (12) backward and

install them loosely to base (16) using two bolts
(15).
a Place washer (17) between adjusters (11),
(12) and base (16).
3. Slide adjusters (11) and (12) forward and install
them loosely to base (16) using two bolts (15).
49 Nm {5.0 kgm}
50-236 PC360LC-10
Removal and installation of seat belt (PC220-K2Q3-924-K-00-A)

the engine.

k Removal and installation work must be done

by a pair of two workers.

6. Remove operator seat (2).

Removal (PC220-K2Q3-520-K-00-A)
1. Pull lever (1) and move operator's seat (2) 4 Operator's seat (2):
backward. 21 kg
7. Remove mounting bolt (6) of seat belt (7) (one
on each side) to remove seat belt (7). [*2]
2. Remove two hexagonal socket head bolts (3)

from the seat rails. [*1]
3. Pull lever (1) again and move operator's seat (2)

forward and fold the backrest forward.
4. Remove two hexagonal socket head bolts (4)
Installation (PC220-K2Q3-720-K-00-A)
from the seat rails. [*1] • Perform installation in the reverse order to
5. Disconnect connector (5). removal.
• Connector (5): Seat belt caution switch (S19) [*1]
3 Mounting bolts (hexagonal socket head)
(3) and (4) of operator's seat (2):
25.5 Nm {2.6 kgm}
[*2]
PC360LC-10 50-237
3 Mounting bolt (6) of seat belt (7):

19.6 – 29.4 Nm {2.0 to 3.0 kgm}
50-238 PC360LC-10
Removal and installation of front wiper assembly (PC220-K710-924-K-00-A)

the engine.
k Set the work equipment lock lever in the

LOCK position.

Removal (PC220-K710-520-K-00-A)
1. Check that wiper blade (1) is at stowed position

(to the R.H. stay).
2. Pull lever (3) to release the lock while holding

handle (2) at right and left of upper part of front
window.
3. Hold lower handle (4) with left hand and upper

handle (5) with right hand, and pull up the front
window, and push it against lock cap (6) at the
rear of cab to lock.
4. Check lever (3) is securely locked.

a Check that the position of arrows on lock
case (7) and lever (3) match.
PC360LC-10 50-239
8. Disconnect connector P31 (14) inside cover

5. Remove lower window (9) by pulling up at knobs
(12).
(8).
9. Remove covers (15) and (16).

6. Remove cover (10) and floor mat (11).

a Insert a flat-head screwdriver in slit (18) at
a One of four mounting screws is covered with left bottom, and pull it upward to remove
cap (13). cover (17) while releasing lug (19).
50-240 PC360LC-10
13.Move wiring harness (23) and remove connector

M05 (24).
14.Open cap (25), remove nut (26) and remove

wiper arm (27).
15.Remove cap (28), nut (29), washer (30) and
packing (31).
11.Remove duct (20).
16.Remove six mounting bolts (32) and remove

wiper motor assembly (33).
12.Remove the mounting bolts of bracket (21) and

keep the bracket with machine monitor (22) at
rear side.
a Ii is not necessary to disconnect the
connectors of machine monitor.
1. Install wiper motor assembly (33).

Adhesive (LT-2)
PC360LC-10 50-241
2. Install packing (31), washer (30) and tighten nut

a Install washer (30) with its chamfered face
toward cab front.
3 Nut (29):
10.8 to 12.7 Nm {1.10 to 1.30 kgm}
5. Check the operation of the wiper arm according

1) Connect connector M05 (24) and P31 (14).
3. Install cap (28) and wiper arm (27).

a Install wiper arm (27) so that clearance "a"
between washer nozzle (34) and wiper blade
(35) becomes following dimension.
• Dimension "a": 7 mm
4. Tighten nut (26) and close cap (25).
3 Nut (26):
11.8 to 15.7 Nm {1.20 to 1.60 kgm}
2) Install lower window (9) by holding knobs (8).
50-242 PC360LC-10
3) Pull lever (3) down to release the lock while 5) When the bottom of front window touches the
holding handle (2) at right and left of front top of lower window, push the upper portion
window stowed in the ceiling. of front window against lock catcher (36) at
the front of the cab to lock.
4) Hold lower handle (4) with left hand and

upper handle (5) with right hand securely, 6) Check lever (3) is securely locked.
and push down the window forward slowly. a Check that the position of arrows on lock
case (7) and lever (3) match.
7) Turn the battery disconnect switch to the ON

position.
8) Check that the work equipment lock lever is
in the LOCK position, and then start the
engine.
9) Check the operation of wiper arm while the
front window is dry.
1] Push wiper switch (37) 3 times
consecutively, check that wiper arm (27)
makes one round trip and then be stowed
to the R.H. stay.
PC360LC-10 50-243
2] Repeat Step 1] again. 3] Repeat Step 1] again.

4] Check that wiper arm (27) makes round
a Rotating direction of motor crank
trips in odd number and then be stowed
defers between Step 1] and Step 2].
to the R.H. stay
Accordingly, check twice.
5] Keep pushing window washer switch (39)
3] Push wiper switch (37), and check
to operate the wiper, and check following.
clearance "b" with trim seal (38) becomes
following dimension when the tip of wiper • No interference between wiper slider
blade (35) reaches to the highest point. (40) and stopper (41) when the tip of
• Dimension "b": 130 mm or less wiper blade (35) reaches to the
highest point. (If interferes, click
sound is heard.)
• No interference between wiper blade
(35) and front window seal (42) when
the tip of wiper blade (35) reaches to
the lowest point.
10)Check the operation of wiper arm while the

front window is wet with washing fluid.
1] Keep pushing window washer switch (39)
for few seconds to wet the front window
throughout, then hand off the switch.
2] Check that wiper arm (27) makes two
round trips and then be stowed to the R.H. 11)If any abnormality is found in the above
stay checks, perform the installation adjustment
of wiper arm in Step 3.
50-244 PC360LC-10
6. Perform the subsequent installation in the

reverse order to removal.
PC360LC-10 50-245
Electrical system
Removal and installation of engine controller assembly (PC220-AP70-924-K-00-A)

Removal (PC300-AP70-520-K-00-A)

2. Remove KCCV assembly (1). For details, see
"Removal and installation of KCCV assembly".
3. Remove step (2) and two frames (3).
4. Remove control valve top cover (4).
5. Remove air cleaner top cover (5) according to

1) Lift up air cleaner top cover (5) to disconnect

it from the air inlet of air cleaner (6).
slantways so that it does not interfere with 9. Remove bolt (10) of wiring harness (9). [*1]
frame (A). 10.Disconnect wiring harness connector CE03 (12)
from engine controller (11). [*2]
hole.
a The connectors are locked with hexagonal
socket head bolts (13) (4 mm).
11.Disconnect wiring harness clamps (14) and (15).
12.Disconnect engine oil pressure switch connector
(16).
13.Disconnect connector E24 (17) from wiring
harness (9) according to the following procedure.
6. After removing the air cleaner top cover, cover [*3]
the air inlet of air cleaner (6) with a vinyl sheet
etc.
hole.
50-246 PC360LC-10
Electrical system
a After disconnecting connector E24 (17), a The connectors are locked with hexagonal
disconnect wiring harness (9) from bracket socket head bolts (22) (4 mm).
(18). 16.Remove two nuts (23) and bracket (18). [*4]
17.Remove four mounting bolts (24) to remove
engine controller (11). [*5]
a Ground cable (25) is also clamped.
a Disconnecting procedure for connector

1) Slide lever (red) (19) toward you to unlock.
2) Grab and pull out connector (17) while
pressing locking tab (20). Installation (PC300-AP70-720-K-00-A)
a Locking tab (20) is on the top of • Perform installation in the reverse order to
connector (17). removal.
[*1]
Installation of wiring harness (9)
1. Install connector ECM (26) of wiring harness (9)
to engine controller (11).
a Push hole (A) on the reverse of wiring
harness (9) into the stud of the mounting bolt
of engine controller (11).
2. Tighten wiring harness (9) with bolt (10).
24 ± 4 Nm {2.45 ± 0.41 kgm}
3. Tighten connector ECM (26) with bolt (22).
3 Hexagonal socket head bolt (4 mm)
(22):
3 ± 1 Nm {0.31 ± 0.1 kgm}
4. Install wiring harness (9) with clamp (21).
24 ± 4 Nm {2.45 ± 0.41 kgm}
14.Disconnect clamp (21) of wiring harness (9). [*1]

15.Disconnect connector ECM (26) of wiring
harness (9) from engine controller (11). [*1]
hole.
[*2]
PC360LC-10 50-247
Electrical system
3 Hexagonal socket head bolt (4 mm) (13): a When tightening bolt (24) of engine controller
3 ± 1 Nm {0.31 ± 0.1 kgm} (11), tighten ground cable (25) together.
24 ± 4 Nm {2.4 ± 0.4 kgm}
[*3]
Installation procedure for connector (17)
1. Install connector of wiring harness (9) to the
clamp of bracket (18).
a When the connector is pushed in fully, the
clamp protrudes from the connector more
than 1.5 mm.
2. Fit connector (17) and slide its outside portion
deep until it is locked.
3. Push in lever (red) (19) deep to lock connector
(17).
[*4]
10 ± 2 Nm {1.0 ± 0.2 kgm}
[*5]
50-248 PC360LC-10
Electrical system
Removal and installation of pump controller assembly (PC220-C3V1-924-K-00-A)

the engine.


a The position of the pump controller is shown in
the figure.
• A: Pump controller
3. Disconnect connectors (4) and (5) according to
a While pressing lock (L1), move lock (L2) to
the other side.
a Slider (B) comes out and the lock is
released.
• Connector (4): Pump controller (CP01)
• Connector (5): Pump controller (CP02)
4. Remove four bolts (6) to remove pump controller
(A).
Removal (PC220-C3V1-520-K-00-A)
1. Pull up cover (1) (three bolts) to remove.

a The connectors and harnesses at the rear
must not be caught.
2. Remove bolts (2) to remove plate (3).
Installation (PC220-C3V1-720-K-00-A)

removal.
Reference: Procedure for removing connector
cover (1)
1. Cut and remove cable tie (2).
PC360LC-10 50-249
Electrical system
2. Move lever (3) upward.
a Right and left sliders (4) are pushed in as far

3. Lightly press part (A) on both sides of connector as they go. (See the left figure shown below.)
cover (1) to release tabs (B). 2. Move lever (3) on connector cover (1) from the
4. Arc connector cover (1) around tab (C) to top position to the left position (locked position)
remove the cover. as shown in the following figure.
a (B) and (C): Tab
a If the sliders and lever are not set as shown
in the following figure, the connector is not
disconnected or locked securely with the
lever. Accordingly, check their positions
again.
a The figure below shows the connector

without connector cover (1).
3. Set tab (C) to the connector and place connector

cover (1).
a Take care that wiring harness (5) be not
caught.
Reference: Procedure for installing connector

cover (1)
1. Push in right and left sliders (4) as far as they
go.
4. Put tabs (B) in to install connector cover (1).
50-250 PC360LC-10
Electrical system
5. Using a new cable tie (2), bind connector cover

(1) and harness (6).
PC360LC-10 50-251
Electrical system
Removal and installation of machine monitor assembly (PC220-Q170-924-K-00-A)

the engine.


Removal (PC220-Q170-520-K-00-A)
1. Pull up front window assembly (1) to the ceiling 5. Remove connector (6) and then remove cover
and lock it. (4).
• Connector (6): Sunlight sensor (P31)
a Check that the front window is securely
locked.
6. Remove duct (10) (one bolt).
3. Remove rubber panel (3) (two bolts).
7. Insert a flat-head screwdriver in slit (7) and pull it

upward to remove cover (9) while releasing lug
(8).
4. Remove three mounting screws of cover (4).
a One of the three screws is covered with cap
(5).
50-252 PC360LC-10
Electrical system

a Hook (17) beneath cover (9) unites cover (9).
a Disconnecting connector (15) first makes
easier to disconnect the other connectors.
• Connector (13): Machine monitor (CM01)
• Connector (14): Machine monitor (CM02)
• Connector (15): Machine monitor (not used)
(CM03)
• Connector (16): Machine monitor (for camera
connection) (CM04)
8. Loosen mounting bolts (19) of cover and duct

assembly (18).
a Loosening mounting bolts (19) first makes
easier to remove machine monitor mounting
bolts.
9. Remove four mounting bolts (11) of machine

monitor (12).
Installation (PC220-Q170-720-K-00-A)

removal.
PC360LC-10 50-253
Electrical system
Removal and installation of pump swash plate sensor (PC220-C3WG-924-K-00-A)
k Park the machine on a level ground, lower • Adjust the pump swash plate sensors. For
the work equipment to the ground, and stop details, see Testing and adjusting, "Special
the engine. function of machine monitor", "Adjustment (front
pump swash plate sensor calibration)" and
k Turn the battery disconnect switch to the "Adjustment (rear pump swash plate sensor
OFF position and remove the key. calibration)".

Removal (PC300-C3WG-520-K-00-A)
1. Open the side cover on the left side of the

machine and remove covers (1) and (2).
2. Disconnect wiring harness clamps (3) and (4).

3. Disconnect connectors (5) and (6).
• Connector (5): Front pump swash plate
sensor (P27)
• Connector (6): Rear pump swash plate
sensor (P28)
4. Remove swash plate sensor mounting bolts (7)
(2 pieces) to remove front pump swash plate
sensor (8) and rear pump swash plate sensor
(9).
Installation (PC300-C3WG-720-K-00-A)

removal.
3 Pump swash plate sensor mounting bolt:
11.8 to 14.7 Nm {1.2 to 1.5 kgm}
50-254 PC360LC-10
Electrical system
Removal and installation of mass air flow and temperature sensor (PC220-
A96H-924-K-00-A)
k Turn the battery disconnect switch to the a Take care that dirt does not enter the air
OFF position and remove the key. cleaner.
Removal (PC300-A96H-520-K-00-A)
1. Open engine hood (1) and remove air cleaner

top cover (2) according to the following
procedure.
Installation (PC300-A96H-720-K-00-A)

removal.
[*1]
1) Lift up air cleaner top cover (2) to disconnect 3 Screw for mass air flow and temperature
it from the air inlet of air cleaner (3). sensor (6):
2) Lift up and remove air cleaner top cover (2) 0.98 to 1.27 Nm {0.1 to 0.13 kgm}
frame (A).

vinyl sheet etc.
2. Disconnect connector P55 (5) of mass air flow
and temperature sensor (4).
3. Remove mass air flow and temperature sensor
(4).[*1]
PC360LC-10 50-255
Electrical system
Removal and installation of KOMTRAX terminal assembly (PC220-Q210-924-K-00-A)

the engine.


a The position of the KOMTRAX terminal is shown
below.
• C: KOMTRAX terminal
a Be careful about connector (7) located
behind cover (6).
Removal (PC220-Q210-520-K-00-A)
1. Remove box (1) (five bolts).

a Disconnect the hose located under box (1).
5. Disconnect connectors (8) to (11).
2. Remove box (2) (three bolts).
a Be careful about connectors (3) and (4) (GPS)
located behind box (2) (for machines • Connector (9): Machine main harness
equipped with 12 V power socket). (CK01).
• Connector (3): 12 V power socket • Connector (10): Machine main harness
intermediate harness (M13A) (CK02).
• Connector (4): 12 V power socket • Connector (11): Communication antenna
intermediate harness (M13B) 6. Remove KOMTRAX terminal (C) (four bolts).
50-256 PC360LC-10
Electrical system
Installation (PC220-Q210-720-K-00-A)

removal.
PC360LC-10 50-257
Electrical system
50-258 PC360LC-10
SHOP MANUAL
HYDRAULIC EXCAVATOR
PC360LC-10
Model Serial Number
PC360LC-10 70001 and up
60 Maintenance standard
8 60 Maintenance standard
PC360LC-10 60-1
Table of contents

60 Maintenance standard................................................................................................................... 60-1
Engine mount ...................................................................................................................... 60-3
Cooling system .................................................................................................................... 60-4
Power train system ..................................................................................................................... 60-5
Swing circle ......................................................................................................................... 60-5
Swing machinery ................................................................................................................. 60-6
Final drive ........................................................................................................................... 60-8
Sprocket............................................................................................................................ 60-10
Idler .................................................................................................................................. 60-14
Track roller ........................................................................................................................ 60-16
Carrier roller ...................................................................................................................... 60-18
Track shoe ........................................................................................................................ 60-19
Hydraulic tank.................................................................................................................... 60-22
Main pump ........................................................................................................................ 60-23
Control valve ..................................................................................................................... 60-24
Swing motor ...................................................................................................................... 60-34
Travel motor ...................................................................................................................... 60-36
PPC valve ......................................................................................................................... 60-39
Solenoid valve ................................................................................................................... 60-50
Attachment circuit selector valve ......................................................................................... 60-51
Center swivel joint .............................................................................................................. 60-52
Work equipment ....................................................................................................................... 60-53
Work equipment................................................................................................................. 60-53
Work equipment cylinder .................................................................................................... 60-62
60-2 PC360LC-10
Engine mount
Engine mount (PC300-H320-034-K-00-A)
PC360LC-10 60-3
Cooling system
Cooling system (PC300-B000-034-K-00-A)
60-4 PC360LC-10
Swing circle
Power train system (ALL-C100-001-K-60-A)
Swing circle (PC300_10-J110-034-K-00-A)
Unit: mm
No. Item Criteria Remedy
Axial clearance of bearing Standard clearance Allowable clearance
1 Replace
(when installed on machine) 0.5 to 1.6 3.2
PC360LC-10 60-5
Swing machinery
Swing machinery (PC300_10-J130-034-K-00-A)
60-6 PC360LC-10
Swing machinery
Unit: mm
Backlash between swing Standard clearance Allowable clearance
1 motor shaft and No. 1 sun
gear 0.18 to 0.28 –
Backlash between No. 1 sun
2 gear and No. 1 planetary 0.15 to 0.51 1.00
gear
Backlash between No. 1
3 planetary gear and ring gear 0.17 to 0.60 1.10
4 planetary carrier and No. 2 0.40 to 0.75 1.20
sun gear
Replace
Backlash between No.2 sun
5 gear and No.2 planetary gear 0.16 to 0.55 1.00
7 planetary carrier and swing 0.07 to 0.23 –
pinion
Backlash between swing
8 pinion and swing circle 0 to 1.21 2.00
Clearance between plate and
9 0.38 to 0.82 –
No. 2 planetary carrier
Standard Repair limit
Outside diameter of oil seal Tolerance Repair by hard
dimension
10 contact surface on swing chrome-plating
0
pinion 140 – or replace
-0.100
PC360LC-10 60-7
Final drive
Final drive (PC300_10-DF10-034-K-00-A)
60-8 PC360LC-10
Final drive
Unit: mm
Backlash between No. 1 Standard clearance Allowable clearance
1 planetary gear and No. 1
sun gear 0.14 to 0.48 1.00
3 planetary carrier and travel 0.06 to 0.25 –
motor
Replace
4 planetary gear and No. 2 0.15 to 0.51 1.00
sun gear
6 planetary carrier and No. 2 0.44 to 0.74 1.6
sun gear
Amount of wear on sprocket Repair limit: 6
7 Rebuild by
tooth
Repair limit build-up welding
Standard dimension
8 Width of sprocket tooth or replace
87 81
PC360LC-10 60-9
Sprocket
Sprocket (PC300-DT60-034-K-00-A)
Unit: mm
Standard dimension Repair limit
1 Wear of tooth tip
336.5 324.5 Rebuild by
2 Thickness of tooth root 28 22 build-up
3 Width of tooth 87 81 welding or
Repair limit: 6 replace
4 Wear of sprocket tooth
(use a full-scale drawing of sprocket tooth shape to judge)
60-10 PC360LC-10
Sprocket
Full-scale drawing of sprocket tooth shape

a Duplicate the drawing onto an OHP sheet at a magnification that restores the scale to the full-size.
PC360LC-10 60-11
Track frame and idler cushion (PC300-DT20-034-K-01-A)
60-12 PC360LC-10
Unit: mm
Standard Repair limit
Tolerance
dimension
Height of idler Track +3
1 guide 123 127
frame -1 Rebuild by
Idler build-up
support 120 ±0.5 118
welding or
Track +4 replace
266 271
frame -1
2 Width of idler guide
Idler
261 – 259
support
Standard dimension
Load at installed Free length x Installed length
3 Recoil spring length of spring Outside diameter Replace
236 kN
805.1 x 262 659
{24,082 kg}
PC360LC-10 60-13
Idler
Idler (PC300-DT90-034-K-00-A)
Unit: mm
Outside diameter of Standard dimension Repair limit
1 protrusion 635 –
2 Outside diameter of tread 590 578 Rebuild by
build-up
3 Depth of tread 22.5 28.5 welding or
4 Thickness of tread — – replace
5 Overall width 190 –
6 Width of tread 44 –
60-14 PC360LC-10
Idler
Unit: mm
Standard Tolerance Standard Allowable
Clearance between shaft dimension Shaft Hole clearance clearance
7 and bushing
-0.225 +0.130 0.201 to
80 –
-0.325 -0.024 0.455
Tolerance Standard Allowable
Standard Replace
interfer- interfer-
Interference between idler dimension Shaft Hole bushing
8 and bushing ence ence
+0.087 -0.027 0.064 to
87.6 –
+0.037 -0.079 0.166
Clearance between bushing Standard clearance Allowable clearance
9 and support
0.68 to 1.22 –
(Total of both sides)
PC360LC-10 60-15
Track roller
Track roller (PC300-DTD0-034-K-00-A)
60-16 PC360LC-10
Track roller
Unit: mm
Outside diameter of outer Standard dimension Repair limit
1 flange 216 –
Outside diameter of inner
2 210 –
flange (double flange)
3 Outside diameter of tread 180 168
4 Thickness of tread 54 48
5 Overall width 250 –
Single Rebuild by
49 – build-up welding
flange
6 Width of tread or replace
Double
47.7 –
flange
Single
27 –
flange
7 Width of flange
Double
27 –
flange
Width of inner flange (double
8 20 –
flange)
Clearance between bushing Standard dimension Repair limit
9 and collar Replace
0.44 – 0.97 –
(Total of both sides)
Clearance between shaft dimension Shaft Hole clearance clearance
10 and bushing
-0.250 +0.186 0.186 to
65 –
-0.350 -0.064 0.536 Replace
Tolerance Standard Allowable bushing
Standard
interfer- interfer-
Interference between roller dimension Shaft Hole
11 and bushing ence ence
+0.108 -0.006 0.014 to
72 –
+0.008 -0.036 0.144
PC360LC-10 60-17
Carrier roller
Carrier roller (PC300-DTJ0-034-K-00-A)
Unit: mm
N- Remedy
Item Criteria
o.
Outside diameter of Standard dimension Repair limit
1 flange
179 –
Outside diameter of
2 152 138
tread
3 Width of tread 50.3 –
4 Thickness of tread 32 25
5 Width of flange 19 –
Clearance between dimension Shaft Hole clearance clearance Replace
6 shaft and bushing
-0.250 +0.100 0.286 to
54 –
-0.280 +0.036 0.380
Interference between dimension Shaft Hole interference interference
7 roller and bushing
+0.117 +0.030 0.057 to
61 –
+0.087 0 0.117
End play of roller Standard clearance Allowable clearance
8
(play of shaft end) 0.5 to 0.7 –
60-18 PC360LC-10
Track shoe
Track shoe (PC300-DTL0-034-K-00-A)
a Portion P shows the link on the side where the bushing is press-fitted.
PC360LC-10 60-19
Track shoe
Unit: mm
1 Link pitch Turn 180
216.3 219.3
deg. or
2 Outside diameter of bushing 66.9 61.9 replace
3 Thickness of bushing 10.8 5.8
4 Link height 116 107
Repair or
Thickness of link (bushing replace
5 press fit part) 30.7 21.7
6 178.4
7 Shoe bolt pitch 140.4
8 76.2
9 Inside width 102
10 Link Overall width 47.8
Adjust or
11 Tread width 42.6
replace
12 Protrusion of pin 4.2
13 Protrusion of regular bushing 5.25
14 Overall length of pin 242
15 Overall length of bushing 158.9
16 Thickness of spacer –
17 Bushing 98 to 264.6 kN {10 to 27 ton}
18 Press fitting Regular pin 147 to 362.6 kN {15 to 37 ton}
–
(*1) force
Master pin 98 to 314 kN {10 to 32 ton}
19
Tightening torque Retightening angle
a. Regular (Nm {kgm}) (deg.)
link Triple grouser 393 ± 39
120 ± 10
shoe {40 ± 4}
20 Shoe bolt Retighten
Tightening Lower limit
torque Retightening angle torque
b. Master link (deg.)
(Nm {kgm}) (Nm {kgm})
– – –
Standard Tolerance Standard
Interference between bushing dimension Shaft Hole interference
21
and link +0.464 +0.074
66.5 0.350 to 0.464
+0.424 0
Interference between regular +0.235 -0.188
22 pin and link 44.6 0.273 to 0.485
+0.085 -0.250
Clearance between regular pin dimension Shaft Hole clearance
23 and bushing
+0.235 +0.915 Adjust or
44.6 0.180 to 0.830 replace
+0.085 +0.415
(*1) Interference between master dimension Shaft Hole interference
24 pin and link +0.030 -0.0188
44.6 0.188 to 0.280
0 -0.250
(1*) Clearance between master pin dimension Shaft Hole clearance
25 and bushing +0.050 +0.915
44.3 0.365 to 0.965
-0.050 +0.415
*1: For the dry type track shoe
60-20 PC360LC-10
Track shoe
Triple grouser shoe (PC300-DTL8-034-K-00-A)
Unit: mm
1 Grouser height
36 24
2 Overall shoe height 47 35
3 Plate thickness 11 Rebuild by
build-up
4 32 welding or
Grouser bottom length
5 26 replace
6 24
7 Grouser tip length 18
8 18
PC360LC-10 60-21
Hydraulic tank
Hydraulic tank (PC300-PM30-034-K-00-A)
60-22 PC360LC-10
Main pump
Main pump (PC300-C200-034-K-00-A)
PC360LC-10 60-23
Control valve
Control valve (PC300-C030-034-K-00-A)
60-24 PC360LC-10
Control valve
PC360LC-10 60-25
Control valve
Unit: mm
Free length Installed Load at Load at
Free
x Outside installed installed
1 Spool return spring length length
diameter length length If
417 N 333 N damaged
54.2 x 34.8 51.2 –
{42.5 kg} {34.0 kg} or
393 N 315 N de-
2 Spool return spring 54.5 x 34.8 51.2 – formed,
{40.1 kg} {32.1 kg} replace
421 N 336 N spring
3 Spool return spring 54.6 x 34.8 51.2 –
{42.9 kg} {34.3 kg}
251 N 201 N
4 Spool return spring 54.9 x 24.2 52.0 –
{25.6 kg} {20.5 kg}
60-26 PC360LC-10
Control valve
PC360LC-10 60-27
Control valve
Unit: m m
Load at Load at
Free length Installed installed Free installed
x Outside length length of length length of If
1 Suction valve spring diameter damaged
spring spring
or
5.5 N 4.4 N de-
46.8 x 7.5 40.6 –
{0.56 kg} {0.45 kg} formed,
1.5 N 1.2 N replace
2 Check valve spring 11.5 x 4.6 8.5 – spring.
{0.15 kg} {0.12 kg}
0.62 N 0.50 N
3 Slow return valve spring 10.3 x 7.7 6.5 –
{0.06 kg} {0.05 kg}
60-28 PC360LC-10
Control valve
PC360LC-10 60-29
Control valve
Unit: mm
Load at Load at If
x Outside damaged
1 Spool return spring length length of length length of or
diameter spring spring de-
19.6 N 15.7 N formed,
50.0 x 14.4 42.0 –
{2.0 kg} {1.6 kg} replace
Check valve spring for 5.9 N 4.71 N spring.
2 regeneration circuit 31.5 x 10.3 19.5 –
{0.6 kg} {0.48 kg}
60-30 PC360LC-10
Control valve
PC360LC-10 60-31
Control valve
Unit: mm
Load at Load at
Merge-divider valve (for LS) x Outside length length of length length of
1 spring diameter spring spring
157 N 126 N
46.6 x 21.8 33.0 –
{16.0 kg} {12.8 kg}
250 N 200 N If
2 Sequence valve spring 70.9 x 18.0 56.0 – damaged
{25.5 kg} {20.4 kg}
or
Merge-divider valve (for main) 178 N 142 N de-
3 64.5 x 32.3 63.0 –
spring {18.1 kg} {14.5 kg} formed,
Hydraulic drift prevention 35.3 N 28.2 N replace
4 33.0 x 12.0 26.0 – spring.
valve check valve spring {3.6 kg} {2.88 kg}
13.7 N 11.0 N
5 Check valve spring 16.4 x 8.9 11.5 –
{1.4 kg} {1.12 kg}
Check valve spring for 5.9 N 4.71 N
6 31.5 x 10.3 19.5 –
regeneration circuit {0.6 kg} {0.48 kg}
50.0 N 40.0 N
7 Travel junction valve spring 30.7 x 20.5 23.0 –
{5.1 kg} {4.08 kg}
60-32 PC360LC-10
Control valve
PC360LC-10 60-33
Swing motor
Swing motor (PC300-J610-034-K-00-A)
60-34 PC360LC-10
Swing motor
Unit: mm
Load at Load at
Free length x Installed installed Free installed If
Outside length length of length length of damaged
1 Check valve spring diameter spring spring or
6.96 N 5.59 N deformed,
66.5 x 25.6 45.0 – replace
{0.71 kg} {0.57 kg} spring.
7.46 N 5.98 N
2 Shuttle valve spring 24.5 x 11.6 14.5 –
{0.76 kg} {0.61 kg}
PC360LC-10 60-35
Travel motor
Travel motor (PC300-C400-034-K-00-A)
60-36 PC360LC-10
Travel motor
PC360LC-10 60-37
Travel motor
Unit: mm
Free length x Installed Load at Load at
Free
Outside installed installed
1 Spool return spring length length
diameter length length
427 N 341 N
58.43 x 30.0 42.0 – If
{43.5 kg} {34.8 kg}
damaged
1.27 N 0.98 N or
2 Check valve spring 33.0 x 13.8 23.0 –
{0.13 kg} {0.10 kg} deformed,
123 N 98 N replace
3 Regulator piston spring 86 x 17 62.6 – spring.
{12.5 kg} {1.0 kg}
230 N 184 N
4 Regulator piston spring 73.6 x 26.2 53.1 –
{23.5 kg} {18.8 kg}
98.1 N 5.96 N
5 Regulator valve spring 29.6 x 9.0 26.0 –
{10.0 kg} {0.58 kg}
60-38 PC360LC-10
PPC valve
PPC valve (ALL-CW10-001-P-00-A)

Work equipment and swing PPC valve (PC300-PL28-034-K-00-A)
PC360LC-10 60-39
PPC valve
60-40 PC360LC-10
PPC valve
Unit: mm
Free
Centering spring x Outside installed installed
1 length length
(for ports P3 and P4) diameter length length
17.7 N 13.7 N If damaged or
42.5 x 15.5 34.0 –
{1.80 kg} {1.40 kg} deformed,
replace spring
Centering spring 29.4 N 23.5 N
2 44.5 x 15.5 34.0 –
(for ports P1 and P2) {3.0 kg} {2.40 kg}
16.7 N 13.7 N
3 Metering spring 26.5 x 8.15 24.9 –
{1.70 kg} {1.40 kg}
PC360LC-10 60-41
PPC valve
Travel PPC valve (PC-C6V0-034-K-00-A)
60-42 PC360LC-10
PPC valve
PC360LC-10 60-43
PPC valve
Unit:mm
x Outside installed Free length installed If damaged
1 Centering spring length
diameter length length or deformed,
48.57 x 108 N 86.3 N replace
32.5 —
15.5 {11 kg} {8.8 kg} spring
26.53 x 16.7 N 13.3 N
2 Metering spring 24.9 —
8.15 {1.7 kg} {1.36 kg}
60-44 PC360LC-10
PPC valve
1st-line attachment PPC valve (with EPC valve) (PC-PL29-034-K-00-A)
(if equipped)
PC360LC-10 60-45
PPC valve
Unit:mm
125 N 100 N replace
33.9 x 15.3 28.4 —
{12.7 kg} {10.2 kg} spring
16.7 N 13.3 N
2 Metering spring 22.7 x 8.10 22.0 —
{1.70 kg} {1.36 kg}
60-46 PC360LC-10
PPC valve
EPC valve (PC300-PL2B-034-K-00-A)

(if equipped)
Unit: mm
Reme-
No. Item Criteria dy
Standard dimension Repair limit If
Load at Load at da-
Installed Free maged
Free length installed installed
length length or
1 Metering spring length length
de-
3.1 N 2.5 N formed,
9.5 8.4 - replace
{0.32 kg} {0.26 kg}
spring
PC360LC-10 60-47
PPC valve
2nd-line attachment PPC valve (PC-PL2A-034-K-00-A)
(if equipped)
60-48 PC360LC-10
PPC valve
Unit:mm
125 N 100 N replace
33.9 x 15.3 28.4 —
{12.7 kg} {10.2 kg} spring
16.7 N 13.3 N
2 Metering spring 22.7 x 8.10 22.0 —
{1.70 kg} {1.36 kg}
PC360LC-10 60-49
Solenoid valve
Solenoid valve (PC300-PQPT-034-K-00-A)
60-50 PC360LC-10
Attachment circuit selector valve (PC300-PQJ3-034-K-00-A)
(if equipped)
Unit: mm
Reme-
No. Item Criteria dy
Standard dimension Repair limit If
Load at Load at da-
Free length Installed installed Free installed maged
x Outside length length of length length of or
1 Spool return spring diameter de-
spring spring
formed,
834 N 667 N replace
132 x 29 114.5 –
{85.0 kg} {68.0 kg} spring.
PC360LC-10 60-51
Center swivel joint
Center swivel joint (PC300-J8E0-034-K-00-A)
Unit: mm
Standard Standard Allowable
1 Clearance between rotor and shaft dimension clearance clearance Replace
80 0.056 to 0.105 0.111
60-52 PC360LC-10
Work equipment
Work equipment (PC300-L410-034-K-00-A)
PC360LC-10 60-53
Work equipment
60-54 PC360LC-10
Work equipment
Unit: mm
Clearance between pin and dimension Shaft Hole clearance clearance
1 bushing connecting revolving
-0.036 +0.157 0.115 to
frame and boom 110 1.0
-0.090 +0.079 0.247
Clearance between pin and -0.036 +0.179 0.117 to
2 bushing connecting boom and 110 1.0
-0.090 +0.081 0.269
arm
Clearance between pin and -0.036 +0.165 0.108 to Replace
3 bushing connecting arm and 90 1.0
-0.090 +0.072 0.255 pin and
link
Clearance between pin and bushing
-0.036 +0.145 0.119 to
4 bushing connecting arm and 90 1.0
-0.090 +0.083 0.235
bucket
5 bushing connecting link and 90 1.0
-0.090 +0.072 0.255
bucket
6 bushing connecting link and 90 1.0
-0.090 +0.069 0.253
link
PC360LC-10 60-55
Work equipment
Unit: mm
Greasing Remedy
No. Item Criteria
interval
Width of boss Width of hinge
Standard
Standard Standard
Tolerance Tolerance clearance
dimension dimension Adjust
Connecting part -0.5 +3
776 780 4.5 to 8.0 clearance to be
7 of revolving
-1.0 0 1.0 mm or less
frame and boom
L7: Adjust with the combination of shim thickness 2.0 with shims
(*2) mm (2), 2.5 mm (1), 3.0 mm (1), and 3.5 mm (1).
500 hours R7: Insert 2.0 mm thickness shim (1).
(*1) +1.5
106 ±1.2 109.3 2.1 to 6.0 Adjust
Connecting part 0
L8: Adjust with the combination of shim thickness 1.0 clearance to be
8 of revolving
(*2) mm (1) and 2.0 mm (2). 1.5 mm or less
frame and boom with shims
cylinder 500 hours R8: Insert 1.0 mm thickness shim (1).
+3
821 ±2.9 827 2.1 to 11.9
-1
Connecting part L9-1: Adjust with the combination of shim thickness 1.0 Adjust
mm (1) and 2.0 mm (2). clearance to be
9 of boom and
boom cylinder (*2) L9-2: Insert 1.0 mm thickness shim (1). 1.5 mm or less
500 hours with shims
R9-1: Insert 1.0 mm thickness shim (1).
R9-2: Insert 1.0 mm thickness shim (1).
+1.5
116 ±1.2 119.3 2.1 to 6.0 Adjust
Connecting part 0
clearance to be
10 of boom and arm L10: Insert 1.0 mm thickness shim (1).
cylinder (*2) 1.5 mm or less
R10: Adjust with the combination of shim thickness 1.0 with shims
500 hours mm (1) and 2.0 mm (2).
-0.3 +0.5
316 320 4.3 to 5.3 Adjust
-0.8 0
Connecting part L11: Insert 2.0 mm thickness shim (1). clearance to be
11
of boom and arm (*2) 1.0 mm or less
R11: Adjust with either shim thickness 2.0 mm (1) or 2.5 with shims
500 hours mm (1) or 3.0 mm (1).
+1.5
Connecting part 116 ±1.2 119.3 2.1 to 6.0
0 Replacement of
12 of arm cylinder L12: Insert 2.0 mm thickness shim (1).
(*2) shim
and arm
500 hours R12: Insert 2.0 mm thickness shim (1).
+1.5
106 ±1.2 109.3 2.1 to 6.0 Adjust
Connecting part 0
clearance to be
13 of arm and L13: Insert 1.0 mm thickness shim (1).
bucket cylinder (*2) 1.5 mm or less
R13: Adjust with the combination of shim thickness 1.0 with shims
500 hours mm (1) and 2.0 mm (2).
+1
Connecting part 345 ±0.5 346 0.5 to 2.5
0 –
14 of link and
(*3) L14: -
bucket
50 hours R14: -
+1
Connecting part 106 ±1.2 110 2.8 to 6.2
15- of bucket 0 –
a cylinder and link (*3) L15a: -
50 hours R15a: -
+0.5
343 - - - Adjust
-0.5
15- Connecting part L15b: Insert 0.8 mm thickness shim (1). clearance to be
b of link and link (*3) 1.0 mm or less
R15b: Adjust with the combination of shim thickness 0.8 with shims
50 hours mm (1) and 1.5 mm (2).
60-56 PC360LC-10
Work equipment
Unit: mm
Greasing Remedy
No. Item Criteria
interval
0.5
345 - - - Adjust
0
Connecting part clearance to be
16 L16: Adjust with the combination of shim thickness 0.8
of arm and link (*3) 1.0 mm or less
mm (1) and 1.5 mm (3).
50 hours with shims
R16: Insert 0.8 mm thickness shim.
0 +0.4 Adjust
330 345 -
Connecting part -0.5 0 clearance to be
17 of arm and L17: – between 0.5 to
(*4)
bucket R17: Adjust with the combination of shim thickness 0.5 1.0 mm with
50 hours mm (4) and 1.0 mm (12). shims
*1: The criteria indicates the L.H. boom cylinder. The position for shim adjustment of R.H. boom cylinder
becomes opposite to that of L.H. boom cylinder.
*2: Use plastic shims (with flange).
*3: Use iron shims (without flange).
*4: Use separated iron shims.
a The number in ( ) next to the shim thickness shows the quantity of shims to be prepared.
PC360LC-10 60-57
Work equipment
Dimension of arm (PC300-L412-034-K-00-A)
60-58 PC360LC-10
Work equipment
Unit: mm
PC360LC–10
No. Tolerance
Measurement point Standard dimension
Shaft Hole
-0.036 +0.100
1 – 100
-0.071 0
+1.5
Arm side 119.3
2 0
Cylinder head side 116 ±1.2
+0.5
Boom side 320
0
3
-0.3
Arm side 316
-0.8
-0.036 +0.1
4 – 110
-0.090 0
5 – 470.6 ±1.0
6 – 236.5 ±0.5
7 – 1,022.4 ±1.0
8 – 3,178 ±3
9 – 2,975.6 ±1.0
10 – 472.5 ±1.0
11 – 731.0 ±0.2
12 – 728.0 ±0.5
13 – 513.6 –
14 – 1,670 –
-0.036 +0.200
15 – 90
-0.090 0
16 – 345 ±0.5
-0.036 +0.054
17 – 90
-0.090 0
0
Arm boss (without bushing) 330
18 -0.5
Arm boss (with bushing press-fitted) 345 –
Min. 1,870 –
19
Max. 3,155 –
PC360LC-10 60-59
Work equipment
Dimension of bucket (PC300-LBK0-034-K-00-A)
60-60 PC360LC-10
Work equipment
Unit: mm
PC360LC–10
No.
Standard dimension Tolerance
1 512.2 ±0.5
2 37.9 ±0.5
3 94 deg. 14′ –
4 513.6 –
5 1,666 –
6 208 –
7 42 deg. –
+0.2
8 f90
0
+0.054
9 f120
0
+0.1
10 f125
0
+1
11 346
0
12 68 –
13 138 –
+0.5
14 525.5
-0.25
15 f26 –
16 f165 –
17 f150 –
18 f200 –
19 137.9 –
20 140.4 –
21 R115 –
22 R100 –
+0.2
23 382
0
24 60 –
25 56 –
PC360LC-10 60-61
Work equipment cylinder
Work equipment cylinder (ALL-PPZ0-001-K-00-A)
Boom cylinder (PC300-L541-034-K-00-A)
Unit: mm
dimen-
Clearance between piston Shaft Hole clearance clearance Replace
1 rod and bushing sion
bushing
-0.036 +0.257 0.083 to
100 0.447
-0.090 +0.047 0.347
Clearance between piston -0.036 +0.190 0.106 to
2 rod support shaft and 100 1.0
bushing -0.071 +0.070 0.261
Replace pin and
Clearance between cylinder bushing
-0.036 +0.190 0.106 to
3 bottom support shaft and 90 1.0
bushing -0.090 +0.070 0.280
Tightening torque of cylinder 373 ± 54 Nm {38.0 ± 5.5 kgm}
4
head
Tightening torque of cylinder
5 piston 294 ± 29.4 Nm {30.0 ± 3.0 kgm} Retighten
6 piston lock screw 58.9 to 73.6 Nm {6.0 to 7.5 kgm}
60-62 PC360LC-10
Arm cylinder (PC300-L950-034-K-00-A)
Unit: mm
dimen-
bushing
-0.036 +0.261 0.083 to
110 0.451
-0.090 +0.047 0.351
Clearance between piston
-0.036 +0.190 0.106 to
bushing -0.090 +0.070 0.280
Replace pin and
-0.036 +0.190 0.106 to
bushing -0.090 +0.070 0.280
Tightening torque of cylinder 530 ± 78.5 Nm {54.0 ± 8.0 kgm}
4
head
PC360LC-10 60-63
Bucket cylinder (PC300-LCD0-034-K-00-A)
Unit: mm
dimen-
bushing
-0.036 +0.257 0.083 to
100 0.447
-0.090 +0.047 0.347
Clearance between piston -0.036 +0.457 0.406 to
bushing -0.090 +0.370 0.547
Replace pin and
-0.036 +0.190 0.106 to
bushing -0.090 +0.070 0.280
Tightening torque of cylinder 373 ± 54.0 Nm {38.0 ± 5.5 kgm}
4
head
60-64 PC360LC-10
SHOP MANUAL
HYDRAULIC EXCAVATOR
PC360LC-10
Model Serial Number
PC360LC-10 70001 and up
80 Appendix
9 80 Appendix
PC360LC-10 80-1
80 Appendix
Table of contents

80 Appendix...................................................................................................................................... 80-1
Air conditioner components ......................................................................................................... 80-3
Precautions for refrigerant..................................................................................................... 80-3
Air conditioner component .................................................................................................... 80-4
Configuration and function of refrigeration cycle...................................................................... 80-7
Outline of refrigeration cycle.................................................................................................. 80-8
Air conditioner unit ............................................................................................................. 80-10
Dual pressure switch .......................................................................................................... 80-17
Air conditioner controller ..................................................................................................... 80-18
Compressor....................................................................................................................... 80-19
Condenser ........................................................................................................................ 80-20
Receiver drier .................................................................................................................... 80-21
Sunlight sensor .................................................................................................................. 80-22
Outer temperature sensor (outside air temperature sensor) ................................................... 80-23
Procedure for testing and troubleshooting ............................................................................ 80-24
Circuit diagram and arrangement of connector pins............................................................... 80-26
System diagram................................................................................................................. 80-28
Input and output signals of the air conditioner controller ......................................................... 80-29
Parts and connectors layout................................................................................................ 80-31
Layout of air conditioner related parts and connectors ........................................................... 80-32
Testing air leakage (duct) .................................................................................................... 80-35
Testing with self-diagnosis function ...................................................................................... 80-38
How to open the electrical system abnormality record screen in service mode of the machine
monitor ................................................................................................................ 80-39
Testing vent (mode) changeover.......................................................................................... 80-41
Testing FRESH/RECIRC air changeover.............................................................................. 80-43
Testing sunlight sensor ....................................................................................................... 80-44
Testing (dual) pressure switch for refrigerant......................................................................... 80-45
Testing relays .................................................................................................................... 80-47
Failure code list related to air conditioner.............................................................................. 80-53
Failure code [879AKA] A/C Inner sensor Open Circuit ........................................................... 80-54
Failure code [879AKB] A/C Inner sensor Short Circuit ........................................................... 80-55
Failure code [879BKA] A/C Outer sensor Open Circuit .......................................................... 80-56
Failure code [879BKB] A/C Outer sensor Short Circuit .......................................................... 80-58
Failure code [879CKA] Ventilating sensor Open Circuit ......................................................... 80-60
Failure code [879CKB] Ventilating sensor Short Circuit.......................................................... 80-61
Failure code [879DKZ] Sunlight sensor Open or Short Circuit ................................................ 80-62
Failure code [879EMC] Ventilating Damper Abnormality ........................................................ 80-64
Failure code [879FMC] Air Mix Damper Abnormality ............................................................. 80-65
Failure code [879GKX] Refrigerant Abnormality .................................................................... 80-66
A-1 Troubleshooting for power supply system (Air conditioner does not operate) ..................... 80-67
A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled) ........................ 80-69
A-3 Troubleshooting for blower motor system (No air comes out or air flow is
abnormal) ............................................................................................................ 80-72
A-4 Troubleshooting for FRESH/RECIRC air changeover ...................................................... 80-74
Troubleshooting with gauge pressure................................................................................... 80-76
Connection of service tool................................................................................................... 80-79
Precautions for disconnecting and connecting air conditioner piping ....................................... 80-81
Handling of compressor oil.................................................................................................. 80-83
80-2 PC360LC-10
80 Appendix
Precautions for refrigerant
Air conditioner components (ALL-K500-001-K-02-A)
Precautions for refrigerant (ALL-K512-012-K-00-A)
k Collect the refrigerant (air conditioner gas: R134a) from the air conditioner circuit before
disconnecting the air conditioner hoses to replace the air conditioner unit or condenser, the air
conditioner compressor, receiver drier, etc.
a Ask a qualified person for collecting, adding and filling operations of the refrigerant (air conditioner gas:
R134a). (Only registered person can work.)
a Never release the refrigerant (R134a) to the atmosphere.
k If refrigerant gas (R134a) gets in your eyes, you may lose your sight. And if it touches your skin,
you may suffer from frostbite. Put on protective eyeglasses, gloves and working clothes with long
sleeves while collecting the refrigerant or filling the air conditioner circuit with the refrigerant.
PC360LC-10 80-3
80 Appendix
Air conditioner component
Air conditioner component (PC300-K500-04D-K-00-A)
80-4 PC360LC-10
80 Appendix
1. Compressor
2. Condenser
3. Receiver drier
4. Hot water piping
5. Hot water return piping
6. Refrigerant piping
7. Dual pressure switch
8. Sight glass
9. Air conditioner controller
11. Recirculation air filter
12. Fresh air filter
13. Machine monitor
14. Sunlight sensor
A: Front vent
B: Rear vent
C: Foot vent
D: Defroster vent
E: Recirculation air inlet
PC360LC-10 80-5
80 Appendix
F: Fresh air inlet

Specification (PC300-K500-030-K-00-A)
Refrigerant R134a
Refrigerant refilling level (g) 750 ± 50
80-6 PC360LC-10
80 Appendix
Configuration and function of refrigeration cycle
Configuration and function of refrigeration cycle (ALL-K500-042-K-00-A)
Cycle Compression Condensation Expansion Evaporation

(Component) (Compressor) (Condenser) (Expansion valve) (Evaporator)
In operator's cab In operator's cab
Engine
Location compartment Front of radiator (Built in air conditioner (Built into air
unit) conditioner unit)
Circulates Lowers temperature
By evaporating
refrigerant gas and Condenses and pressure of
refrigerant, absorb
increases its refrigerant to refrigerant liquid and
heat from the air
temperature and discharge heat gas for easy
around the evaporator,
Function pressure so that it absorbed in evaporation with
and cools the
can be liquefied evaporator. throttle. Controls flow
surrounding air.
easily in condenser. (condensation of rate, too.
(Evaporation of
(Compression of refrigerant) (Throttle action of
refrigerant)
refrigerant) refrigerant)
Gas o gas Gas o liquid Liquid, gas o gas
State of Liquid o liquid, gas
refrigerant Adiabatic Constant pressure Constant pressure
Adiabatic expansion
compression change change
PC360LC-10 80-7
80 Appendix
Outline of refrigeration cycle
Outline of refrigeration cycle (ALL-K500-04A-K-00-A)
• The refrigerating cycle performs the following four processes. The refrigerant is liquefied and gasified
repeatedly while it is circulated in the cycle.
Compression (Compressor)
• The compressor sucks in the refrigerant that has been vaporized in the evaporator and compresses it into
a state where it can be easily liquefied at the ambient temperature.
• The gaseous refrigerant sucked into the compressor cylinder is compressed to a temperature and
pressure at which it can be easily liquefied when cooled to the ambient temperature.
Condensation (Condenser)
• The condenser cools and liquefies the high pressure and high-temperature gaseous refrigerant sent from
the compressor.
• The heat released to the outside from the condenser is called condensation heat.
• The amount of condensation heat is the sum total of the heat absorbed by the evaporator from the air in
the cab and the quantity of the work applied (the value converted into a heat quantity) by compression of
the compressor.
• The refrigerant liquefied in the condenser is dehydrated in the modulator and cooled further in the sub-cool
section to increase the cooling efficiency.
• In the compression cycle, the gaseous refrigerant and liquid refrigerant coexist.
• The temperature (condensation temperature) and the pressure (condensation pressure) at which the
gaseous refrigerant is liquefied are proportional to each other.
(The condensation pressure varies depending on the condensation temperature of the refrigerant)
Expansion (Expansion valve)

• The expansion valve reduces the liquid refrigerant pressure to a level where liquid refrigerant can be
easily evaporated by the throttle action (*1).
• The action of reducing the liquid refrigerant pressure to a level where it can be easily evaporated before it
is sent to the evaporator is called expansion.
• The expansion valve, which reduces the refrigerant pressure, also adjusts the refrigerant flow rate
simultaneously.
• The quantity of the liquid refrigerant that can be evaporated in the evaporator depends on the amount of
heat (refrigeration load) to be removed under the specific evaporation temperature (evaporation pressure).
• The expansion valve controls the refrigerant feed rate so that the optimum quantity of liquid refrigerant is
supplied to the evaporator.
*1: Throttle action
• If there is a narrow section in the passage through which liquid is flowing at a constant rate, a resistance to
the flow will be generated.
The liquid expands when it passes through the narrow section and rushes into the passage where the
sectional area is larger, and consequently, its pressure and temperature are reduced.
• No heat is transferred from or to the outside during the throttle action.
Evaporation (Evaporator)
• The evaporator evaporates the liquid refrigerant (superheated vapor).
• The refrigerant evaporates, while absorbing an amount of heat necessary for evaporation (evaporation
heat) from the air around the cooling fins (air in the cab).
• After the heat has been removed, the cooled air is sent into the cab by the blower fan, reducing the
temperature inside the cab.
• The mist refrigerant that has been sent from the expansion valve coexists with the evaporated refrigerant
in the evaporator
• The temperature (evaporation temperature) and the pressure (evaporation pressure) at which the liquid
refrigerant is evaporated are proportional to each other.
• The compressor sucks in the evaporated refrigerant in order to keep the pressure level in the evaporator
as low as possible so that the liquid refrigerant can be evaporated at a much lower temperature.
Relationship between refrigerant and defective air conditioning

• The refrigerant circulates in the refrigeration circuit while repeating the refrigeration cycle to expel the heat
from inside the cab.
80-8 PC360LC-10
80 Appendix
Outline of refrigeration cycle
• If there is an insufficient quantity of refrigerant, all of it will be evaporated while it is passing through the
evaporator. This causes evaporator efficiency to deteriorate, which will result in defective air conditioning.
• If there is excessive refrigerant, not all of it will be evaporated and part of it will be sucked into the
compressor in liquid form, which will cause the compressor to compress the liquid and may damage the
components.
• If water gets into the refrigeration circuit, it will freeze at a small hole in the expansion valve, lower the
refrigerant flow, and may result in defective air conditioning.
PC360LC-10 80-9
80 Appendix
Air conditioner unit
Air conditioner unit (ALL-K540-041-K-00-A)
a This air conditioner unit is auto temperature control type.
A: Refrigerant inlet (from condenser)

B: Refrigerant outlet (to compressor)
80-10 PC360LC-10
80 Appendix
C: Hot water inlet

D: Hot water outlet
E: Recirculation air hole
F: Fresh air hole
G: Front air vents
H: Rear air vents
J: Foot level air vents
K: Defroster vents
1. Evaporator
2. Heater core
3. Expansion valve
4. Blower fan, blower motor
5. Air mix servomotor
6. Air mix door
7. Vent (mode) changeover servomotor
Vent (mode) changeover door
8. Rear door
9. Foot door
10. Defroster door
11. FRESH/RECIRC air changeover servomotor
12. FRESH/RECIRC air changeover door
13. Power transistor
14. Evaporator temperature sensor
15. Insidel air temperature sensor
a The door is the same as the damper.
Function (ALL-K540-042-K-00-A)
• The air conditioner unit consists of evaporator (1) and heater core (2), and is used to cool down or warm
up the air in the cab.
Temperature control
• When the temperature control switch on the machine monitor is operated, the set temperature data is sent
to the air conditioner controller that is located at the rear of the operator's seat.
• The air conditioner controller controls air mix servomotor (5) to change the angle of air mix door (6) so that
the set temperature is reached
Over-cooling (Freezing) prevention

• Evaporator temperature sensor (14) varies the resistance of its resistor according to temperature.
• The air conditioner controller converts the change in resistance of evaporator temperature sensor (14) into
the change in voltage to determine the temperature of evaporator (1).
• The air conditioner controller performs control to prevent freezing of the evaporator (1) by operating the
compressor clutch relay (*) to stop the compressor.
*: For details of compressor clutch relay, see "Parts and connectors layout".
Air flow adjustment

• When the air flow adjusting switch on the machine monitor is operated, the set air flow data is sent to the
air conditioner controller. The air conditioner controller controls blower motor (4) by using power transistor
(13) in order to adjust the air flow.
Vent (mode) changeover

• When a vent switch on the machine monitor is operated, mode data is sent to the air conditioner controller.
The air conditioner controller controls mode changeover servomotor (7) to adjust the opening and closing
angles of mode changeover doors (8) to (10) so that the selected vents are available.
PC360LC-10 80-11
80 Appendix
FRESH/RECIRC air changeover

• When the FRESH/RECIRC air selector switch on the machine monitor is operated, the set data of
FRESH/RECIRC air changeover is sent to the air conditioner controller. The air conditioner controller
controls FRESH/RECIRC air changeover servomotor (11) to open or close FRESH/RECIRC air
changeover door (12).
Automatic mode of air conditioner

• Inside air temperature sensor (15) detects the temperature inside operator's cab based on changes in
resistance. The air conditioner controller converts the change in resistance of inside air temperature
sensor (15) into the change in voltage to determine the room temperature.
The air conditioner controller checks the voltage of inside air temperature sensor (15) and controls the
room temperature so that it matches the setting made on the machine monitor.
The air conditioner controller also takes into consideration data from the sunlight sensor and the outer
sensor (outside air temperature sensor) when adjusting the room temperature.
Changeover pattern of the vent (mode) changeover door
Rear door (8) Foot door (9) Defroster door (10)
Opening Opening Opening
and closing Angle and closing Angle and closing Angle
door door door
Front Close 0 Close 0 Close 0
Front and rear Open 25 Close 0 Close 0
Front, rear and Open Open
25 35 Close 0
Air vent foot
mode Foot Open 25 Open 53 Close 0
Foot and Open Open Open
25 23 38
defroster
Defroster Open 25 Open 0 Open 38
Selection pattern of air mix door (6)
Set temperature Opening and closing door Angle (°C)
Max. Cool Close 0
Max. Hot Open 80
80-12 PC360LC-10
80 Appendix
Functions of major components (ALL-K540-001-K-00-A)
a For details of the numbers in the following sentence, see “Air conditioner unit”.
Evaporator (ALL-K549-042-K-00-A)
• Evaporator (1) is cooled by the low-pressure, low-temperature refrigerant gas being sent from expansion
valve (3).
• Air from blower motor (4) is cooled and dehumidified when passing through the evaporator fins.
Heater core (ALL-K547-042-K-00-A)

• Heater core (2) is warmed by the hot water (engine coolant) being sent from the engine. Air from blower
motor (4) is warmed when passing through fins of the heater core (2).
Evaporator temperature sensor (ALL-K5FF-042-K-00-A)

• Evaporator temperature sensor (14) is installed to evaporator (1) with the holder. Its resistance changes in
accordance with the temperature change of the evaporator. The air conditioner controller determines the
temperature of evaporator (1) from voltage changes of evaporator temperature sensor (14) to prevent
freeze of the evaporator.
PC360LC-10 80-13
80 Appendix
Servomotor (ALL-K5D2-042-K-00-A)
a Servomotors are used to adjust the temperature (air mix) and to perform vent (mode) changeover.
• When a switch on the machine monitor is operated, the air conditioner controller applies 24V power
between servomotor terminal B (6) and servomotor terminal A (7). (Rotation direction switches according
to the polarity of supply voltage.) )
• The servomotor contains a variable resistor, and its resistance value changes as the motor rotates.
• The air conditioner controller applies a voltage of 5 V to the variable resistor and determines the motor
rotation angle from the potential difference.
• When the door (damper) reaches the position specified by each switch, the air conditioner controller stops
the supply of current to the servomotor, then the corresponding door stops.
• When the air conditioner controller cannot recognize the potential difference that corresponds to the
command to the servomotor, it generates a air conditioner failure code to inform the machine monitor of
failure in air conditioner system. Failure code [879EMC] or [879FMC] is displayed on the electrical system
failure record screen of the machine monitor.
a FRESH/RECIRC air changeover servo motor does not feature a variable resistance, and therefore,
does not have a self-diagnosis function.
a Do not try to drive a servomotor by supplying power directly between servomotor terminals (6) and (7)
during inspection.
80-14 PC360LC-10
80 Appendix
Expansion valve (ALL-K548-041-K-00-A)
A: When evaporator outlet temperature is high

B: When evaporator outlet temperature is low
C: From capacitor (high-pressure refrigerant)
D: To compressor (low-pressure refrigerant)
1. Expansion valve
1a. Needle valve
1a-1. Diaphragm
1a-2. Thermoprobe
1b. Spring
2. Refrigerant gas
3. Evaporator
Structure
• Box-type expansion valve (1) consists of needle valve (1a), spring (1b), etc.
• Refrigerant gas (2) is sealed in the diaphragm chamber (hatched area) outside diaphragm (1a-1) of
needle valve (1a).
• The expansion valve (1) converts high-pressure and high-temperature liquid refrigerant from the receiver
drier to low-pressure, low-temperature misty refrigerant through the throttle action.
• It controls the flow rate of refrigerant by changing the level of throttling depending on the temperature in
the cab.
• The temperature of the air blown out of the air vent is adjusted depending on the flow rate of refrigerant
circulating in the evaporator (3).
Operation (ALL-K548-044-K-00-A)
• Thermoprobe (1a-2) senses the refrigerant temperature after it passes through the evaporator (3).
PC360LC-10 80-15
80 Appendix
• After the refrigerant passes through evaporator (3), its temperature is transferred to the refrigerant gas (2)
in the diaphragm chamber (hatched area) through the thermoprobe (1a-2).
• The pressure of the refrigerant gas (2) sealed in the diaphragm chamber (hatched area) changes in
response to the temperature change of the thermoprobe (1a-2), which therefore changes the force (Fg)
pushing the needle valve (1a).
• The opening level of the needle valve (1a) is determined based on the balance between the reaction force
exerted by the spring (1b) in a rightward direction, and the force (Fg) of the refrigerant gas (2) pushing the
needle valve (1a) through the diaphragm (1a-1) in a leftward direction.
• The refrigerant flow rate flowing from the receiver drier to evaporator (3) is determined based on the
opening level of needle valve (1a).
When evaporator (3) outlet temperature is high: [When not cooled yet: Condition (A) in the figure]
• The pressure of the refrigerant gas (2) in the diaphragm chamber is high and the volume is increased.
• The force (Fg) of the refrigerant gas (2) pushing the needle valve (1a) is increased, and the needle valve
(1a) moves leftward.
• As a result, the opening level of the needle valve (1a) is increased and the refrigerant flow rate to the
evaporator (3) is increased to improve cooling capacity. (Condition (A) in previous figure)
When evaporator (3) outlet temperature is low: [When cooled already: Condition (B) in the figure]
• The pressure of the refrigerant gas (2) in the diaphragm chamber is low and the volume is decreased.
• The force (Fg) of the refrigerant gas (2) pushing the needle valve (1a) is reduced, and the needle valve
(1a) is moved rightward by the reaction force of spring (1b).
• The opening level of the needle valve (1a) is reduced and the refrigerant flow rate to the evaporator (3) is
reduced to lower the cooling capacity. (Condition (B) in previous figure)
80-16 PC360LC-10
80 Appendix
Dual pressure switch
Dual pressure switch (ALL-K5FG-044-K-00-A)
a The dual pressure switch is mounted on the air conditioner hose under the floor.
• The dual pressure switch turns "OFF" when the refrigerant circuit pressure becomes abnormally low or
abnormally high.
• When the dual pressure switch turns "OFF", the air conditioner controller turns the compressor clutch
relay "OFF". As a result, the compressor's magnet clutch is released and air conditioner components are
protected.
Function (ALL-K5FG-042-K-00-A)
a LA or lower: Abnormally low pressure

a HA or higher: Abnormally high pressure
LA: 0.20 MPa {2 kg/cm2}
LB: 0.02 MPa {0.2 kg/cm2}
HA: 3.14 MPa {32 kg/cm2}
HB: 0.59 MPa {6 kg/cm2}
PC360LC-10 80-17
80 Appendix
Air conditioner controller
Air conditioner controller (ALL-K5G4-041-K-00-A)
a See "System Diagrams" for details regarding input/output signals.
80-18 PC360LC-10
80 Appendix
Compressor
Compressor (ALL-K590-041-K-00-A)
A: Refrigerant inlet (from air conditioner unit)

B: Refrigerant outlet (to condenser)
1. Pulley
2. Magnetic clutch
3. Relief valve
Specification (ALL-K590-044-K-00-A)
Number of cylinders - Bore x Stroke (mm) 10 - 32 x 20.8

Piston capacity (cc/rev) 157.3
Max. allowable speed (rpm) 6,000
Compressor oil DENSO: ND-OIL8 (For R134a)
Compressor oil refill capacity (cc) 180
• The compressor circulates the refrigerant and compresses the gaseous refrigerant from the evaporator
into a misty refrigerant at high pressure and high temperature so that it will be easily regenerated
(liquefied) at the normal temperature.
• Calling into account of the evaporator temperature and refrigerant pressure, the air conditioner controller
activates magnetic clutch (2) built in the compressor.
• When magnetic clutch (2) is engaged, the power of the engine rotates the compressor shaft along with
pulley (1) to drive the compressor.
PC360LC-10 80-19
80 Appendix
Condenser
Condenser (PC400-K580-041-K-00-A)
A: Refrigerant inlet (from compressor)

B: Refrigerant outlet (to receiver drier)
Specification (PC400-K580-030-K-00-A)
Fin pitch (mm) 4.0

Height x width x thickness (mm) 357 x 540 x 16
Max. working pressure (MPa {kg/cm2} 3.6 {36}
Function (PC400-K580-042-K-00-A)
• The condenser cools and liquefies the high pressure and high temperature misty refrigerant sent from the
compressor.
a If the fin is crushed or is clogged with dust, heat exchange efficiency is reduced and complete liquefaction
of refrigerant becomes impossible.
If the heat exchange efficiency is reduced, pressure in the refrigerant circulation circuit will be increased,
applying extra load to the engine or reducing the cooling effect. Take extreme care not to crush or damage
the fins when hangling it or performing daily inspection.
80-20 PC360LC-10
80 Appendix
Receiver drier
Receiver drier (PC400-K5E2-041-K-00-A)
A: Refrigerant inlet (from condenser)

B: Refrigerant outlet (to air conditioner unit)
PC360LC-10 80-21
80 Appendix
Sunlight sensor
Sunlight sensor (ALL-K5FH-041-K-00-A)
1. Connector
2. Sensor
Function (ALL-K5FH-042-K-00-A)
• The sunlight sensor is mounted on top of the machine monitor.

• It detects the strength of incident sunlight and sends signals to the air conditioner controller.
• When performing automatic air conditioning, the air conditioner controller controls the blower motor and
the air mix servomotor with the data of the sunlight sensor in order to adjust the temperature and air flow.
80-22 PC360LC-10
80 Appendix
Outer temperature sensor (outside air temperature
sensor)
Outer temperature sensor (outside air temperature sensor) (ALL-K55C-041-K-00-A)
1. Connector
2. Sensor
Function (ALL-K55C-042-K-00-A)
• The outside (air) temperature sensor is installed in the cooling unit.

• The outside air temperature sensor has feature of change in resistance by temperature change, therefore,
can detect the ambient temperature.
• The air conditioner controller detects the ambient temperature by converting the changes in the resistance
of the outside air temperature sensor into voltage changes.
• When performing automatic air conditioning, the air conditioner controller controls the blower motor and
the air mix servomotor with the data of the outside (air) temperature sensor in order to adjust the
temperature and air flow.
PC360LC-10 80-23
80 Appendix
Procedure for testing and troubleshooting
Procedure for testing and troubleshooting (ALL-K500-422-K-00-A)
The air conditioner is provided with self-diagnosis functionality in order to provide for inspection of its main
components. Specifically, the operation of sensors and servomotors can be examined.
If a troubled section is detected, every part of that section must be inspected.
1. After basic check, find the troubled section according to the detected trouble of the air conditioner.
2. Narrow down the sections with the self-diagnosis function (See “Check with self-diagnosis”).
If, however, the entire air conditioner unit fails to operate, inspect for problems with the supply of power to
the air conditioner controller and with CAN communication between the machine monitor and the air
conditioner controller.
If any part of the air conditioner unit can operate, it will indicate that the air conditioner controller is
receiving power normally and that CAN communication between the machine monitor and the air
conditioner controller is normal.
3. After finding out the troubled section, inspect the component parts in that section and repair the troubled
part.
Basic testing and troubleshooting sequence
*1: By error display or abnormal display on "Electrical Systems" screen on the machine monitor.
*2: Simple checking of refrigerant volume through sight glass.
Start up the engine, set the air conditioner switch to ON, and then wait for five minutes before proceeding with
the inspection.
A) If the continuous stream of bubbles can be seen, the system contains insufficient refrigerant.
B) If the bubbles can be seen intermittently, the refrigerant volume is sufficient.
80-24 PC360LC-10
80 Appendix
Procedure for testing and troubleshooting
C) If no bubbles can be seen (i.e., the liquid is perfectly clear), the system contains too much refrigerant or no
refrigerant at all.
The above should be treated as general guidelines as certain exceptions do exist.
See "Troubleshooting with gauge pressure" and use gauge pressure to determine whether or not the
condition is normal.
S: Sight glass condition
R: Receiver drier internal condition
LR: Liquid refrigerant
*3: If any leakage of refrigerant is occurring, the compressor oil circulating within the air conditioner circuit will
definitely be leaking from the same point.
In such a case, retighten in accordance with the table of retightening torques from "Precautions for
disconnecting and connecting air conditioner piping."
*4: Start the engine and perform the check with the air conditioner switch set to ON.
PC360LC-10 80-25
80 Appendix
Circuit diagram and arrangement of connector pins
Circuit diagram and arrangement of connector pins (PC400-K500-051-K-02-A)
80-26 PC360LC-10
80 Appendix
Circuit diagram and arrangement of connector pins
a Diffuser servomotor means vent (mode) changeover servomotor.

a SERVOMOTOR OF INSIDE/OUTSIDE AIR means FRESH/RECIRC air changeover servomotor.
a Frost sensor means evaporator temperature sensor.
PC360LC-10 80-27
80 Appendix
System diagram
System diagram (PC220-K5F0-051-K-00-A)
a This air conditioner unit is auto temperature control type.
80-28 PC360LC-10
80 Appendix
Input and output signals of the air conditioner controller
Input and output signals of the air conditioner controller (ALL-K5G4-03C-K-00-A)
Controller connector: AMP 025 - 32PM

Wiring harness connector: ACECU
AMP025 - 32PF
Input/Output
Pin No. Symbol Signal name
signal
1 +Bback Backup power supply Input
2 – (*1) –
3 SS Sunlight sensor Input
4 THOUT Outside air temperature sensor Input
5 THF Evaporator temperature sensor Input
6 THI Inside air temperature sensor Input
7 POT5 V Servomotor potentiometer power supply (5 V) Output
8 BWFB Blower feedback signal Input
9 PTRB Power transistor control signal Output
10 CAN_H CAN communication signal (H) Input/output
11 CAN_L CAN communication signal (L) Input/output
12 – (*1) –
13 MRFA Fresh/recirculated air servomotor terminal A Output
14 MRFB Fresh/recirculated air servomotor terminal B Output
15 MAMA Air mix servomotor terminal A Output
16 MAMB Air mix servomotor terminal B Output
17 +24 V 24 V power supply Input
18 – (*1) –
19 SAM Air mix servomotor potentiometer signal Input
20 SVI Vent (mode) changeover servomotor potentiometer signal Input
21 PRESS SW Dual pressure switch Input
22 – (*1) –
23 – (*1) –
24 – (*1) –
25 GNDS Sensor GND Input
26 GND GND Input
27 – (*1) –
28 – (*1) –
29 RLCC Compressor clutch relay Output
30 – (*1) –
31 MV1A Vent (mode) changeover servomotor terminal A Output
32 MV1B Vent (mode) changeover servomotor terminal B Output
Function (ALL-K5G4-042-K-00-A)
• Operation of air conditioner controller

1. Performing CAN communication with the machine monitor, the air conditioner controller controls the air
conditioner unit by inputting switches associated with air conditioning.
2. The air conditioner controller controls three servomotors located inside the air conditioner unit in order to
adjust the temperature (airmix), perform vent (mode) changeover, and perform FRESH/RECIRC air
changeover.
3. The air conditioner controller controls the ON/OFF condition of the compressor clutch relay (i.e., a switch
for activating the compressor).
4. The air conditioner controller controls the air flow volume using the power transistor.
a The power transistor has an overcurrent prevention fuse in it.
PC360LC-10 80-29
80 Appendix
Input and output signals of the air conditioner controller
5. The air conditioner controller detects the evaporator temperature using the evaporator temperature
sensor.
6. In order to prevent freezing of the evaporator, the air conditioner controller controls the compressor by
turning the compressor clutch relay ON and OFF.
a When the dual pressure switch detects a pressure abnormality (i.e., turns OFF), the air conditioner
controller turns the compressor clutch relay OFF, and therefore, the compressor stops operating.
7. When performing automatic air conditioning, the air conditioner controller controls the inside (air)
temperature to the set temperature and adjust the air flow according to the data from the sunlight sensor,
the outside air temperature sensor, and the inside air temperature sensor.
8. The air conditioner controller has the self-diagnosis function. If any abnormality is detected, the controller
notifies it to the machine monitor by the CAN communication. Then, failure code [879***] is displayed on
the "Electrical Systems" screen of the electrical system on the machine monitor.
80-30 PC360LC-10
80 Appendix
Parts and connectors layout
Parts and connectors layout (PC300-K500-055-K-00-A)
• Three fuses related to the air conditioner are located in the fuse box at the right rear of the operator's seat.
• The air conditioner unit is installed behind the rear cover at the rear of the operator's seat.
k Park the machine on a level ground, swing the upper structure by 90 ° , lower the work equipment
to the ground stably, and stop the engine.
k Turn the battery disconnect switch to the "OFF" position and pull out the key.
a Note connector numbers and installed positions before disconnecting wiring and hoses.
Item No. to be
Connector No. Remarks Location
referred to
AC01 Intermediate connector Rear right of cab 2.
AC02 Intermediate connector Rear right of cab 2.
AC03 Air conditioner compressor Engine 7.
ACECU Engine controller Rear of cab 2.
CM01* Machine monitor Front of cab 5.
CM02 Machine monitor Front of cab 5.
F01 Fuse box Rear right of cab 1.
Dual pressure switch
P17 Under cab 6.
a Turn the upper structure by 90 °.
P18 Outside air temperature sensor Cooling unit 8.
P31 Sunlight sensor Machine monitor 4.
R21 Relay Rear of cab 2.
[2] Power transistor Air conditioner unit 3.
[5]* FRESH/RECIRC air changeover
Air conditioner unit 3.
servomotor
[6]* Inside air temperature sensor Air conditioner unit 3.
Evaporator temperature sensor (frost
[7]* Air conditioner unit 3.
sensor)
*: Connectors that are not involved in the troubleshooting
PC360LC-10 80-31
80 Appendix
Layout of air conditioner related parts and connectors
Layout of air conditioner related parts and connectors (PC300-K500-04D-K-01-A)
1. Fuses in the fuse box F01: Open the cover of fuse box at the right rear of the operator's seat.
• No.10(20 A): Fuse for power supply to blower (fan) and air conditioner compressor
• No.14(5 A): Fuse for air conditioner unit, air conditioner controller and primary side power supply of
electromagnetic clutch relay of air conditioner compressor
• No.19(5 A): Fuse for power supply (backup power supply) to air conditioner compressor
2. Air conditioner controller: *1

• AC01: Intermediate connector
• AC02: Intermediate connector
• ACECU: Air conditioner controller connector
• R21: Air conditioner compressor electromagnetic clutch relay

a [2], [5], [6] and [7] are numbers of unlabeled connectors.
80-32 PC360LC-10
80 Appendix
a On the rear side of the air conditioner unit (Connectors other than connector [2] installed on machine
cannot be disconnected.)
[2]: Power transistor (*2) connector
[5]: FRESH/RECIRC air changeover servomotor connector
[6]: Inner sensor (inside air temperature sensor) connector
[7]: Evaporator temperature sensor connector
*2: Power transistor
4. Sunlight sensor
P31: Sunlight sensor connector
5. Machine monitor
• CM01–CM04: Machine monitor connector
a Connector CM03: (not used)
a Connector CM04: (for camera connection)
6. Dual pressure switch

a Turn 90 degrees to remove the cab undercover.
• P17: Dual pressure switch connector
PC360LC-10 80-33
80 Appendix
7. Air conditioner compressor

a Open the engine hood.
• AC03: Air conditioner compressor connector
*3: Air conditioner compressor ground
8. Outside air temperature sensor

P18: Outside air temperature sensor connector
80-34 PC360LC-10
80 Appendix
Testing air leakage (duct)
Testing air leakage (duct) (ALL-K5D0-001-K-00-A)
k Place the machine on a level ground, lower the work equipment to the ground and stop the engine.
k Turn the battery disconnect switch to the OFF position and remove the key.
a Note the connector numbers and installed positions before disconnecting wiring harnesses and hoses.
Check (ALL-K5D0-360-K-00-A)
1. Lift front window assembly (1) to the ceiling and lock it.
a Check that the front window is securely locked.
3. Remove floor mat (3).
4. Remove cover (4) first, and then remove cover (5).
6. Remove cap (7-1).

a Disconnect the sunlight sensor connector from the rear of cover (7).
8. Remove drink box (8) (five bolts).

a Disconnect the hose under drink box (8).
9. Remove magazine box (9) (three bolts).
a Be careful about connectors (10) and (11) behind magazine box (9). (for machines equipped with 12 V
power socket)
• Connector (10): 12 V power socket intermediate harness (M13A)
• Connector (11): 12 V power socket intermediate harness (M13B)
10.Pull up cover (12) (three bolts) to remove.
a The connectors and wiring harnesses at the rear must not be caught.
PC360LC-10 80-35
80 Appendix
11.Remove cover (13) (seven bolts).

a Be careful about connector (14) behind cover (13).
12.Check the following ducts and pins for disconnection.

• Front duct (15)
• Defroster duct (16)
• Rear duct (17)
• Fresh air inlet duct (18) and pin (19)
80-36 PC360LC-10
80 Appendix
PC360LC-10 80-37
80 Appendix
Testing with self-diagnosis function
Testing with self-diagnosis function (ALL-Q19Y-001-K-00-A)
Testing outline (ALL-Q19Y-360-K-00-A)
The air conditioner controller performs various self-diagnosis such as inside air temperature sensor, outside
air temperature sensor, evaporator temperature sensor, temperature control system, vent (mode) changeover
system, sunlight sensor, and refrigerant pressure with the dual pressure switch. If an error is detected on the
temperature control system, vent (mode) changeover system, or refrigerant, the machine monitor
momentarily shows a warning screen and then "Air conditioner system state monitor" lights up continuously.
a The machine monitor displays the system state monitor "!" when an error occurs in the communication
between the machine monitor and the air conditioner controller.
a The system performs self-diagnosis of various sensors. If any failure is detected, a failure code is
displayed on the "Electrical Systems Abnormality Record" screen in the service mode of the machine
monitor.
a Once a failure is detected in the self-diagnosis, the error condition is not canceled even if the failed part
returns to normal.
Turning the starting switch "OFF" clears a failure.
a FRESH/RECIRC air changeover servomotor is not checked in the self-diagnosis.
80-38 PC360LC-10
80 Appendix
How to open the electrical system abnormality record
screen in service mode of the machine monitor
How to open the electrical system abnormality record screen in service

mode of the machine monitor (PC220-Q19Y-100-K-00-A)
• Overview of machine monitor operating procedure
Standard screen
Press [1], [2], and [3] in this order while holding down O [4].
Service menu (Mode)
Press O [F3] twice. Press [F6].
03 Abnormality Record
Press O [F3] once. Press [F6].
02 Electrical systems abnormality record screen
• Detailed description of machine monitor operating procedure
1. On the normal operation screen, while pressing number key [4], press [1], [2], and [3] in this order.
2. Validate the selection by pressing [F6].
3. Press [F3] twice on the Service Menu screen to select 03 "Abnormality Record".
5. Press [F3] once on the Failure Record screen to select 02 "Electrical System Abnormality Record".
PC360LC-10 80-39
80 Appendix
How to open the electrical system abnormality record
screen in service mode of the machine monitor
a For details, see the failure code list related to air conditioner.
Failure code Failure (Displayed on screen) Remarks
Air Conditioner Inner Sensor Open
879AKA
Circuit
*
Air Conditioner Inner Sensor Short
879AKB
Circuit
Air Conditioner Outer Sensor Open
879BKA
Circuit
Air Conditioner Outer Sensor Short
879BKB
Circuit
879CKA Ventilating Sensor Open Circuit
*
879CKB Ventilating Sensor Short Circuit
Sunlight Sensor Open or Short
879DKZ
Circuit
879EMC Ventilation Damper Abnormality *
879FMC Air Mix Damper Abnormality *
879GKX Refrigerant Abnormality
Air Conditioner Model Selection
DAZ9KQ Abnormality See Chapter 40, "Troubleshooting
CAN2 Disconnection (Air by failure code" **
DAZQKR Conditioner ECU)
*: Troubleshooting cannot be performed while the controller is mounted on the machine since the connector
cannot be checked.
**: Troubleshooting is not performed by the air conditioner unit but by the machine monitor.
a The air conditioner inner sensor means the inside (air) temperature sensor.
a The air conditioner outer sensor means the outside (air) temperature sensor.
a The ventilating sensor means the evaporator temperature sensor (frost sensor).
a The ventilation damper means the vent (mode) changeover damper (door).
a The air mix damper means the temperature adjustment (air mix) damper (door).
80-40 PC360LC-10
80 Appendix
Testing vent (mode) changeover
Testing vent (mode) changeover (ALL-K5FR-001-K-00-A)
Testing (ALL-K5FR-360-K-00-A)
1. Remove drink box (1) (five bolts).

a Disconnect the hose under drink box (1).
2. Remove magazine box (2) (three bolts).
a Be careful about connectors (3) and (4) behind magazine box (2). (for machines equipped with 12 V
power socket).
• Connector (3): 12 V power socket intermediate harness (M13A)
• Connector (4): 12 V power socket intermediate harness (M13B)

a Be careful about connector (7) behind cover (6).
PC360LC-10 80-41
80 Appendix
Testing vent (mode) changeover
5. Remove ducts (8) and (9).
6. Turn the battery disconnect switch to the "ON" position.

7. Start the engine and turn the air conditioner power "ON".
8. Operate the vent changeover switch on the machine monitor.
9. Check the opening/closing operation of rear door (11) and defroster door (12) of air conditioner unit (10).
10.After finishing the inspection, turn the starting switch to the OFF position.
80-42 PC360LC-10
80 Appendix
Testing FRESH/RECIRC air changeover
Testing FRESH/RECIRC air changeover (ALL-K5D2-001-K-00-A)
Testing (ALL-K5D2-360-K-00-A)
1. Open outside air filter cover (1) and remove outside air filter (2).
2. Start the engine and turn the air conditioner power "ON".
3. Operate the FRESH/RECIRC air selector switch on the machine monitor.
4. Check the opening/closing operation of FRESH/RECIRC air changeover rear door (3) through the fresh
air inlet on the left side of the cab.
5. After finishing the inspection, turn the starting switch to the OFF position.
PC360LC-10 80-43
80 Appendix
Testing sunlight sensor
Testing sunlight sensor (PC220-K5FH-001-K-00-A)
Testing (PC220-K5FH-360-K-01-A)
1. Remove the machine monitor cover. For details, see "Testing air leakage (duct)", Steps 6 and 7.
2. Check connector P31 at the rear of the sunlight sensor. (Check whether the connector is coming off.)
3. Disconnect connector P31, remove the sunlight sensor, and measure the voltage between the terminals
on the sensor side using a circuit tester in voltage range.
• Approximate voltage of sunlight sensor unit
0.55 V: Direct sunlight
0.45 V: Cloudy
0.4 V: Indoors
80-44 PC360LC-10
80 Appendix
Testing (dual) pressure switch for refrigerant
Testing (dual) pressure switch for refrigerant (PC220-K5FG-001-K-00-A)
Testing (PC300-K5FG-360-K-00-A)
• If [879GKX] "Refrigerant Abnormal" is displayed by the self-diagnosis (on "Air-conditioning System"

screen of "Abnormality Record" in the machine monitor), test the dual pressure switch connector P17.
• To reset the self-diagnosis system (detection of abnormality), the starting switch must be turned OFF.
• The dual pressure switch is ON when the refrigerant pressure is normal, and OFF when it is abnormal.
a If ambient temperature drops to 0°C or below, refrigerant pressure will also subsequently decrease.
Accordingly, there is a possibility that the dual pressure switch is OFF. In such a case, the dual
pressure switch unit is not defective but normal.
1. Perform swing of 90 deg.
2. Remove the cab undercover.
3. Disconnect the dual pressure switch connector P17.
4. Check if the resistance between the switch-side terminals of connector P17 are shorted (ON). (If not
shorted (OFF), dual pressure switch is detecting an abnormal refrigerant pressure.)
a If the dual pressure switch is OFF, attach a pressure gauge to the high-pressure line of the air
conditioner compressor and check the refrigerant pressure. See "Connection of service tool" and
"Troubleshooting with gauge pressure".
a If the refrigerant pressure is normal, the dual pressure switch is defective.
• (Dual) pressure switch
LA: 0.20 MPa {2 kg/cm2 }

LB: 0.02 MPa {0.2 kg/cm2 }
HA: 3.14 MPa {32 kg/cm2 }
HB: 0.59 MPa {6 kg/cm2 }
PC360LC-10 80-45
80 Appendix
Testing (dual) pressure switch for refrigerant
k When replacing the dual pressure switch, refrigerant must be collected in advance.
a If resistance between the switch-side terminals from connector P17 is shorted (ON), perform
"Troubleshooting for compressor and refrigerant system".
80-46 PC360LC-10
80 Appendix
Testing relays
Testing relays (PC220-K5FE-001-K-00-A)
Testing (PC220-K5FE-360-K-03-A)
1. Check contact R21 of connector (for disconnection).

2. Turn the starting switch ON (do not start the engine), turn the main power of the air conditioner ON, and
turn the air conditioner switch. If the compressor relay is normal, it is turned ON. Check whether it clicks.
a The air conditioner controller will not turn on the compressor clutch relay in the following cases.
1) When the evaporator temperature is below 3 °C (depending on the input voltage from the evaporator
temperature sensor).
2) When the pressure switch detects abnormality (it is turned OFF).
• Checking relay unit

a Since no T-adapter is available, it is impossible to check the relay while the voltage is applied to the coil
actually.
Compressor clutch relay (CCRL), connector (AC04)
1. The coil resistance between terminals (1) and (2) is approximately 370 to 530 z.
2. While voltage (DC 20 to 30 V) is not applied between terminals (1) (+) and (2), terminals (3) and (4) are
connected.
3. While voltage (DC 20 to 30 V) is applied between terminals (1) (+) and (2), terminals (3) and (5) are
connected.
PC360LC-10 80-47
80 Appendix
Troubleshooting chart 1
Troubleshooting chart 1 (PC220-3840-421-A-00-A)
Numbers in T represent the item numbers in the troubleshooting quick reference table.
1. Lowered cooling performance
2. Lowered heating performance
80-48 PC360LC-10
80 Appendix
Troubleshooting chart 2 (PC220-3840-421-A-01-A)
1. During cooling, the blower fan motor does not operate or the rotation speed does not match the air flow
setting.
Probable cause Check method Remedy
Check the connector for disconnection. Repair broken parts
Wire breakage or defective and connect
connection See "Parts and connectors layout". correctly
Operate the fan switches in order and check the fan
Defective blower fan motor speed. Replace
See "Air conditioner unit".
Defective power transistor Operate the fan switches in order and check the fan
Replace
(PTR) speed.
2. During cooling, the blower fan motor is normal but the flow of air is very light.
Large duct resistance Check the filter for clogging and the duct for crushing. Repair
Air leakage through duct Check duct joints.
Repair
joints See "Testing air leakage (duct)".
Obstruction at evaporator Check evaporator for stain and obstruction Remove obstruction
inlet and clean
Defective evaporator Evaporator is frozen.
temperature sensor, Sensor fixing clip inspection, sensor contaminated
defective contact of Repair or replace
evaporator temperature Inspect the air conditioner hose around the pressure
switch for frost.
sensor, defective expansion
valve* (when freezing has advanced even further)
*: The evaporator temperature sensor and expansion valve are located inside the air conditioner unit.
3. Pressure abnormality (high-pressure/low-pressure) during cooling.
Repair leaking part,
then charge with
Insufficient refrigerant
proper quantity of
Check the refrigerant volume through sight glass. refrigerant again
Specifically, perform checking with the gauge manifold Collect refrigerant,
connected. then fill up with
Overcharge with refrigerant
proper quantity of
refrigerant again
Normal pressure range
Low-pressure: Approx. 0.13 to 0.2 MPa {1.3 to 2.0 kg/
cm2 }
Judgment by pressure at See Troubleshooting
inlet/outlet of compressor High pressure: Approx. 1.5 to 1.7 MPa {15 to 17 kg/cm2 with gauge pressure
}
Temperature in operator's cab: 30 to 35 °C , Engine
speed: Approx. 1,500 rpm
PC360LC-10 80-49
80 Appendix
4. During cooling, the compressor will not operate smoothly, or at all.

a See "Troubleshooting of compressor system (Air is not cooled)".
Troubled
part
Deflection of belt is large.
Compressor See "Checking and adjusting air
belt
Slack of belt conditioner compressor belt tension" in Adjust tension
the "Testing and adjusting" in Chapter
30.
Trouble in compressor Slip of belt Repair or replace
Compressor Insufficient compressor oil See "Handling
Heating of compressor
Seizing on compressor compressor oil".
Drop of battery voltage Slip of clutch Charge battery
Open or short circuit in coil Inspect with multimeter (10 to 20 z) Replace
Magnet
Check ground cable and joints.
clutch Wire breakage or defective
connection of ground wire See "Troubleshooting for compressor Repair
and refrigerant system".
Defective compressor clutch
Relay See "Testing relays" Replace
relay
See
Refrigerant Low/high pressure (Operation See "Troubleshooting with gauge "Troubleshooting
pressure of pressure switch) pressure". with gauge
pressure".
See "Troubleshooting for compressor
Pressure and refrigerant system".
Defective pressure switch Replace
switch See "Testing refrigerant (dual) pressure
switch".
5. During heating, blower fan motor is normal but air flow alone is insufficient.
Large duct resistance Check the filter for clogging and the duct for crushing. Repair
Air leakage through duct Check the duct joints by referring to "Testing air leakage
Repair
joints (duct)."
Clogging of heater core fins Check heater core fins for clogging Clean
6. Engine coolant temperature or volume abnormalities during heating or cooling
Low engine coolant Warm up engine, and then check engine coolant
temperature temperature Find out cause
Low engine coolant level Check coolant level in radiator Add coolant
Insufficient circulation of Check engine coolant piping for clogging.
engine coolant Bleed air and correct
(Hose, pipe and core)
The connection of IN and
OUT heater hoses is in Check the destination of heater hoses Correct
reverse.
7. Fan speed abnormalities during cooling
See "Replacing fan belt" in "Testing and adjusting" in
Fan speed is low Replace
Chapter 30.
80-50 PC360LC-10
80 Appendix
8. Other abnormalities
Probable cause Check method Remarks
Temperature cannot be Select manual mode and change temperature setting.
controlled
Vent (mode) changeover is Common to cooling
See "Testing vent (mode) changeover".
not possible. and heating
FRESH/RECIRC air cannot
See "Testing FRESH/RECIRC air changeover".
be changed over
Excessive compressor oil See "Handling of compressor oil".
Cooling only
Water leakage into the cab Clogging of drain hole
PC360LC-10 80-51
80 Appendix
Information in troubleshooting table
Information in troubleshooting table (ALL-5170-421-A-03-A)

Information in troubleshooting table
Failure Failure symptom that appears on machine
Related information Information on occurred failure or troubleshooting
[Information described]
• Procedure
• Measuring location
1
a "Between A and B" denotes measuring voltage or resistance, etc.
Probable cause of failure between A and B.
(Perform troubleshooting • Criteria to determine probable causes
according to these.) • Remarks for judgment of Good or No good
[Notes on troubleshooting]
2 (1) pin number description sequence and tester lead handling
For troubleshooting, connect the plus (+) and minus (-) tester leads
as shown below unless otherwise specified.
• Connect the plus (+) lead to a pin or harness indicated in the
front.
• Connect the minus (-) lead to a pin or harness indicated in the
rear.
3 Defective — (2) Example of troubleshooting done by testing multiple items
a Normal in 1 but abnormal in 2
At this time, "Defective component" shown at left 3 is applied.
a If a wiring harness is burnt, replace it.

[Defective wiring harness]
• Open circuit
Connection of connector is defective or wiring harness is broken.
• Ground fault
A harness not to be connected to the ground (earth) circuit comes into contact with the ground (earth)
circuit or chassis accidentally.
• Hot short circuit
A harness not to be connected to the power (24V) circuit comes into contact with the power (24V) circuit
accidentally.
• Short circuit
An independent wire in the harness abnormally comes into contact with another independent wire. (poor
insulation at connector and others)
Related circuit diagram

This is the extracted circuit diagram related to failure
• Indicates connector No., and pin No.
• See "Circuit diagram and arrangement of connector pins" and "Parts and connectors layout" for
connector location
• The circuit diagram shows the size and colors of wires.
W: White, B: Black, R: Red, G: Green, Y: Yellow, L: Blue, V: Purple, P: Pink, O: Orange, Br: Brown, Gr:
Gray, Sb: Sky blue, Lg: Light green, Dg: Dark green, Ch: Dark brown
a When there are two colors
Example: WY: Yellow line on white background
a The number before the wire color indicates the wire size.
• N.C.: Normally closed (Normally ON)
• [1], [2], ... are numbers of unlabeled connectors.
• The arrow (io) indicates their rough installation position on the machine.
80-52 PC360LC-10
80 Appendix
Failure code list related to air conditioner
Failure code list related to air conditioner (ALL-K500-441-K-00-A)

Compo-
Failure Failure (Displayed on screen) nent in Action Category
Remarks
code charge level of record
A/C Inner Sensor Open Electrical Troubleshooting cannot be
879AKA MON –
Circuit system performed while the controller
is mounted on the machine
A/C Inner Sensor Short Electrical
879AKB MON – since the connector cannot
Circuit system
be checked.
A/C Outer Sensor Open Electrical
879BKA MON –
Circuit system
A/C Outer Sensor Short Electrical
879BKB MON –
Circuit system
Ventilating Sensor Open Electrical Troubleshooting cannot be
879CKA MON –
Circuit system performed while the controller
Ventilating Sensor Short Electrical
879CKB MON – since the connector cannot
Circuit system
be checked.
Sunlight Sensor Open or Electrical
879DKZ MON –
Short Circuit system
Ventilation Dumper Electrical Troubleshooting cannot be
879EMC Abnormality MON L01 system performed while the controller
Electrical
879FMC Air Mix Dumper Abnormality MON L01 since the connector cannot
system
be checked.
Electrical
879GKX Refrigerant Abnormality MON L01 system
A/C Model Selection Electrical
DAZ9KQ Abnormality MON –
system See Chapter 40,
"Troubleshooting by failure
Electrical
DAZQKR CAN2 Discon (Aircon ECU) MON L01 code"
system
a The air conditioner inner sensor means the inside (air) temperature sensor.
a The air conditioner outer sensor means the outside (air) temperature sensor.
a The ventilating sensor means the evaporator temperature sensor (frost sensor).
a The vent damper means the vent (mode) changeover damper (door).
a The Air Mix Damper means the temperature adjustment (air mix) damper (door).
a Troubleshooting for the troubles which do not display failure codes is explained after failure code
[879GKX].
• Troubleshooting for power supply system (Air conditioner does not operate)
• Troubleshooting for compressor and refrigerant system (Air is not cooled)
• Troubleshooting for blower motor system (No air comes out or air flow is abnormal)
• Troubleshooting for FRESH/RECIRC air changeover
PC360LC-10 80-53
80 Appendix
Failure code [879AKA] A/C Inner sensor Open Circuit
Failure code [879AKA] A/C Inner sensor Open Circuit (PC220_10-879AKA-400-A-00-A)
Action Air conditioner inside air temperature sensor disconnection

Failure code
level Failure
— (Machine monitor system)
879AKA
Details of • Air conditioner controller detected disconnection in inside (air) temperature sensor.
failure
• The air conditioner controller sends information about the inside (air) temperature sensor
Action of disconnection to the machine monitor via CAN communication.
controller • Stops the air conditioner if it is in automatic mode.
• The air conditioner does not operate in automatic mode because of a disconnection in the
Problem on air conditioner inside air temperature sensor.
machine (The air conditioner can be operated in manual mode)
• Check whether this failure code is displayed in the "Electrical Systems" screen of the
Related electrical system in the service mode of the machine monitor.
information • Troubleshooting cannot be performed since the connector portion of the air conditioner
inside (air) temperature sensor cannot be checked while the controller is installed on the
machine.
Defective air If no failures are found by the above checks, the air conditioner controller may be
1 conditioner defective.
If no failures are found by the above checks, the air conditioner unit may be
Defective air defective.
2
conditioner unit
80-54 PC360LC-10
80 Appendix
Failure code [879AKB] A/C Inner sensor Short Circuit
Failure code [879AKB] A/C Inner sensor Short Circuit (PC220_10-879AKB-400-A-00-A)
Action Air conditioner inside air temperature sensor short circuit

Failure code
level Failure
879AKB
Details of • Air conditioner controller detected short circuit in inside (air) temperature sensor.
failure
• The air conditioner controller sends information about the inside (air) temperature sensor
Action of short circuit to the machine monitor via CAN communication.
controller • Stops the air conditioner if it is in automatic mode.
• The air conditioner does not operate in automatic mode because of a short circuit in the
Problem on air conditioner inside air temperature sensor.
machine (The air conditioner can be operated in manual mode)
information • Troubleshooting cannot be performed since the connector portion of the air conditioner
inside (air) temperature sensor cannot be checked while the controller is installed on the
machine.
2
conditioner unit
PC360LC-10 80-55
80 Appendix
Failure code [879BKA] A/C Outer sensor Open Circuit
Failure code [879BKA] A/C Outer sensor Open Circuit (PC220_10-879BKA-400-A-00-A)
Action Air conditioner outside air temperature sensor disconnection

Failure code
level Failure
879BKA
Details of • Air conditioner controller detected disconnection in outside (air) temperature sensor.
failure
• The air conditioner controller sends information about the outside (air) temperature
Action of sensor disconnection to the machine monitor via CAN communication.
controller • Continues control of air conditioner in automatic mode, ignoring data of outside (air)
temperature sensor.
• Since the air conditioner outside temperature sensor has a disconnection, outside
Problem on temperature is not counted in automatic mode.
machine (The air conditioner is not affected in manual mode)
electrical system in the service mode of the machine monitor.
• For connectors and other parts, see "Parts and connectors layout".
• Since connector ACECU of the air conditioner controller has small pins and does not
Related have a T-adapter, carry out troubleshooting by using the intermediate connector
information (Although the intermediate connector does not have a T-adapter either, it does have large
pins).
• If the air conditioner wiring harness between connector ACECU of the air conditioner
controller and the intermediate connector needs to be replaced, the air conditioner unit
must be replaced.
1. Turn starting switch to "OFF" position.
Defective outside
1 air temperature
sensor Between P18
Resistance 25°C Approx 1.7 kz
(male) (1) and (2)
Open circuit or 2. Disconnect connector AC01.
2 short circuit in a Same as above, if resistance is normal
wiring harness
Between AC01
(female) (7) and (8)
a If cause 2 is not the cause for the failure, this check is not required.
Breaking of 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors P18 and AC01.
3 (Wire breakage or Between AC01 (female) (7) and P18
defective contact of (female) (1) Max. 1 z
connectors) Resistance
Between AC01 (female) (8) and P18
5
conditioner unit
80-56 PC360LC-10
80 Appendix
Failure code [879BKA] A/C Outer sensor Open Circuit
Circuit diagram related to air conditioner outside air temperature sensor
PC360LC-10 80-57
80 Appendix
Failure code [879BKB] A/C Outer sensor Short Circuit
Failure code [879BKB] A/C Outer sensor Short Circuit (PC220_10-879BKB-400-A-00-A)
Action Air conditioner outside air temperature sensor short circuit

Failure code
level Failure
879BKB
Details of • Air conditioner controller detected short circuit in outside (air) temperature sensor.
failure
• The air conditioner controller sends information about the outside (air) temperature
Action of sensor short circuit to the machine monitor via CAN communication.
controller • Continues control of air conditioner in automatic mode, ignoring data of outside (air)
temperature sensor.
• Since air conditioner outside temperature sensor has short circuit, outside temperature is
Problem on not counted in automatic mode.
pins).
must be replaced.
1. Turn starting switch to "OFF" position.
Defective outside
1 air temperature
sensor Between P18
(male) (1) and (2)
Open circuit or 2. Disconnect connector AC01.
2 short circuit in a Same as above, if resistance is normal
wiring harness
Between AC01
(female) (7) and (8)
a If cause 2 is not the cause for the failure, this check is not required.
Short-circuiting of 1. Turn starting switch to OFF position.
3 2. Disconnect connectors P18 and AC01.
harness
Between AC01 (female) (7) and (8), or
Resistance between P18 (female) (1) and (2) Min. 1 Mz
Ground fault in 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors P18 and AC01.
4
(Contact with GND Between ground and AC01 (female) (8)
circuit) Resistance or P18 (female) (1) Min. 1 Mz
6
conditioner unit
80-58 PC360LC-10
80 Appendix
Failure code [879BKB] A/C Outer sensor Short Circuit
Circuit diagram related to air conditioner outside air temperature sensor
PC360LC-10 80-59
80 Appendix
Failure code [879CKA] Ventilating sensor Open Circuit
Failure code [879CKA] Ventilating sensor Open Circuit (PC220_10-879CKA-400-A-00-A)
Action Evaporator temperature (frost) sensor disconnection

Failure code
level Failure
879CKA
Details of • Air conditioner controller detected disconnection in evaporator temperature (frost) sensor.
failure
• Th air conditioner controller sends information about the evaporator temperature (frost)
Action of sensor disconnection to the machine monitor via CAN communication.
controller • Stops the air conditioner.
Problem on • The air conditioner does not operate due to a disconnection in the evaporator
machine temperature (frost) sensor.
information • Troubleshooting cannot be performed since the connector portion of the evaporator
temperature (frost) sensor cannot be checked while the air conditioner unit is installed on
the machine.
2
conditioner unit
80-60 PC360LC-10
80 Appendix
Failure code [879CKB] Ventilating sensor Short Circuit
Failure code [879CKB] Ventilating sensor Short Circuit (PC220_10-879CKB-400-A-00-A)
Action Evaporator temperature (frost) sensor short circuit

Failure code
level Failure
879CKB
Details of • Air conditioner controller detected short circuit in evaporator temperature (frost) sensor.
failure
• The air conditioner controller sends information about the evaporator temperature (frost)
Action of sensor short circuit to the machine monitor via CAN communication.
controller • Stops the air conditioner.
Problem on • The air conditioner does not operate due to a short circuit in the evaporator temperature
machine (frost) sensor.
information • Troubleshooting cannot be performed since the connector portion of the evaporator
temperature (frost) sensor cannot be checked while the air conditioner unit is installed on
the machine.
2
conditioner unit
PC360LC-10 80-61
80 Appendix
Failure code [879DKZ] Sunlight sensor Open or Short
Circuit
Failure code [879DKZ] Sunlight sensor Open or Short Circuit (PC220_10-879DKZ-

400-A-00-A)
Action Sunlight sensor disconnection or short circuit
Failure code
level Failure
879DKZ
Details of • Air conditioner controller detected disconnection or short circuit in sunlight sensor.
failure
• The air conditioner controller sends information about sunlight sensor disconnection or
Action of short circuit to the machine monitor via CAN communication.
controller • Continues control of the air conditioner in automatic mode, ignoring sunlight sensor data.
• Since the air conditioner sunlight sensor has a disconnection or short circuit, sunlight
Problem on strength is not counted in automatic mode.
pins).
must be replaced.
1. See "Testing sunlight sensor".
Defective sunlight Direct sunlight Approx. 0.55 V
1 Between sunlight
sensor Voltage Cloudy Approx. 0.45 V
sensor terminals
Indoor Approx. 0.4 V
Breaking of 2. Disconnect connector P31.
harness a See "Testing sunlight sensor".
2 (Wire breakage or Between P31 (female) (1) and AC01
defective contact of (female) (10) Max. 1 z
connectors) Resistance
Between P31 (female) (2) and AC01
4
conditioner unit
80-62 PC360LC-10
80 Appendix
Failure code [879DKZ] Sunlight sensor Open or Short
Circuit
Circuit diagram related to sunlight sensor
PC360LC-10 80-63
80 Appendix
Failure code [879EMC] Ventilating Damper Abnormality
Failure code [879EMC] Ventilating Damper Abnormality (PC220_10-879EMC-400-A-00-A)
Action Abnormality in vent (mode) changeover damper servomotor

Failure code
level Failure
(Machine monitor system)
L01 879EMC
Details of • Air conditioner controller judged from potentiometer voltage of servomotor that vent
failure (mode) changeover damper servomotor is not operating.
Action of • The air conditioner controller sends information about the abnormality in vent (mode)
controller changeover damper to the machine monitor via CAN communication.
Problem on • Vent (mode) cannot be changed but air conditioner can be operated.
machine
information • Troubleshooting cannot be performed since the connector portion of vent (mode)
changeover damper servomotor cannot be checked while the air conditioner unit is
installed on the machine.
2
conditioner unit
80-64 PC360LC-10
80 Appendix
Failure code [879FMC] Air Mix Damper Abnormality
Failure code [879FMC] Air Mix Damper Abnormality (PC220_10-879FMC-400-A-00-A)
Action Abnormality in air mix (temperature regulation) damper

Failure code
level Failure servomotor
L01 879FMC (Machine monitor power train control system)
Details of • The air conditioner controller judged from the potentiometer voltage of the servomotor
failure that the air mix (temperature regulation) damper servomotor is not operating.
Action of • The air conditioner controller sends information about the air mix damper abnormality to
controller the machine monitor via CAN communication.
Problem on • The air conditioner does not operate since temperature cannot be regulated.
machine
• Method of reproducing failure code: Turn starting switch ON position.
Related
information
• Troubleshooting cannot be performed since the connector part of the air mix damper
servomotor cannot be checked while the air conditioner unit is installed on the machine.
2
conditioner unit
PC360LC-10 80-65
80 Appendix
Failure code [879GKX] Refrigerant Abnormality
Failure code [879GKX] Refrigerant Abnormality (PC220_10-879GKX-400-A-00-A)
Action Refrigerant (dual) pressure switch abnormality

Failure code
level Failure
(Machine monitor system)
L01 879GKX
Details of • Air conditioner controller detected that dual pressure switch was OFF (abnormal).
failure
• The air conditioner controller sends information about the refrigerant pressure
abnormality to the machine monitor via CAN communication.
Action of • The air conditioner controller turns OFF compressor clutch relay, since refrigerant
controller pressure is abnormal.
(The air conditioner compressor stops)
Problem on • The air conditioner (cooling) does not operate.
machine
• For each connector and other parts, see "Parts and connectors layout".
pins).
must be replaced.
Defective 1. See "Testing (dual) pressure switch for refrigerant".
1 refrigerant (dual)
k When replacing the dual pressure switch, be sure to collect refrigerant in
pressure switch
advance. See "Precautions for refrigerant".
Breaking of
2. Disconnect connector AC01 and P17.
harness
Between P17 (female) (1) and AC01
2 (Wire breakage or (female) (6) Max. 1 z
defective contact of Resistance Between P17 (female) (2) and ground
connectors) Max. 1 z
a Looseness and rust of T06
4
conditioner unit
Circuit diagram related to (dual) pressure switch for refrigerant
80-66 PC360LC-10
80 Appendix
A-1 Troubleshooting for power supply system (Air
conditioner does not operate)
A-1 Troubleshooting for power supply system (Air conditioner does not
operate) (PC220_10-FJ0-400-A-00-A)
Failure • Trouble: Air conditioner does not operate due to power supply system failure.
• If failure code [DAZQKR] is displayed on machine monitor, perform this troubleshooting
first.
a The machine monitor, engine controller, pump controller, and air conditioner controller are
connected via CAN communication.
• "DAZQKR" is displayed on operation screen of machine monitor in the following cases. In
this section, 1) and 2) of the following are explained.
1) The air conditioner controller is receiving no power.
2) The air conditioner controller is malfunctioning.
3) No communication is possible between the air conditioner controller and the machine
monitor.
a For 3), see failure code [DAZQKR].
• Turn starting switch to ON position and check whether failure code [DAZQKR] is
displayed on machine monitor and whether CAN communication condition is abnormal.
Related This type of abnormal status indicates that CAN communication cannot be performed
information between the air conditioner controller above the air conditioner unit and the machine
monitor.
• Referring to "Parts and connectors layout", check fuse No. 14 (5 A) in fuse box F01 for
breakage.
• Ground cable of air conditioner is connected in machine wiring harness together with
electrical equipment of machine.
• In cases where fuses are blown when the A/C switch is pressed, see "Troubleshooting for
compressor and refrigerant system."
have a T-adapter, carry out troubleshooting by using the intermediate connector
(Although the intermediate connector does not have a T-adapter either, it does have large
pins).
must be replaced.
Defective wiring 2. Set battery disconnect switch to OFF position.
1 harness (ground) 3. Disconnect connector AC02.
Between (1) (black) on harness side of
Resistance connector AC02 and chassis ground Max. 1 z

2 Blown fuse 2. Referring to "Parts and connectors layout", check fuse No. 14 (5 A) in fuse box
F01 for breakage.
a If fuse described in related information is broken, replace it.
2. Set battery disconnect switch to OFF position.
Defective wiring 3. Disconnect connector AC02.
3
harness 4. Set battery disconnect switch to ON position.
Between connector AC02 (female) (4) 20 to 30 V
Voltage
(red) and (1) (black)
PC360LC-10 80-67
80 Appendix
A-1 Troubleshooting for power supply system (Air
conditioner does not operate)

a If the fuse is blown again during the above test, carry out the following
procedure.
Ground fault in
machine wiring
2. Set battery disconnect switch to OFF position.
4 harness
3. Disconnect connector AC02.
(Contact with GND 4. Remove fuse No. 14 of fuse box F01.
circuit) Between connector AC02 (female) (4)
Resistance (red) and ground, or between F01-14 Min. 1 Mz
and ground
Breaking of 1.Turn starting switch to OFF position.
harness 2.Set battery disconnect switch to OFF position.
3.Disconnect connector AC02.
5 (Wire breakage or
4.Remove fuse No. 14 of fuse box F01.
Between connector AC02 (female) (4)
connectors) Resistance Max. 1 Mz
(red) and F01-14
Defective air Replace air conditioner controller.
6 conditioner
controller
7
conditioner unit
Defective machine If no abnormality is found in the checkup of potential causes 1 - 7, the machine
8
monitor monitor is defective.
Circuit diagram related to power supply
80-68 PC360LC-10
80 Appendix
A-2 Troubleshooting for compressor and refrigerant
system (Air is not cooled)
A-2 Troubleshooting for compressor and refrigerant system (Air is not

cooled) (PC400-FKE-400-A-Z0-A)
Failure Air is not cooled due to compressor or refrigerant system failure.
• When engine is started and A/C switch is pressed on air conditioner screen of machine
Problem on monitor, air is not cooled as displayed on screen.
machine • Air conditioner compressor does not operate.
• Referring to inspection by self-diagnosis function, display the "Electrical Systems" screen
on the machine monitor to check whether an inappropriate refrigerant is being used by
confirming that failure code [879GKX] is displayed. If an inappropriate refrigerant is being
used, the compressor will not be turned on, and air will not be cooled.
a Abnormal refrigerant pressure indicates that "Signal ((21) of connector ACECU) from the
dual pressure switch is not grounded".
• In certain cases, the air conditioner will not turn on at 3°C or lower (normal).
Related • When air does not come out, see "Troubleshooting of blower motor system".
information • For each connector and fuse, see "Parts and connectors layout".
a A T-adapter is provided only for the connector AC03.
• Since T-adapter is not provided for the connector ACECU of the air conditioner controller
and the pin size is small, use the intermediate connector for troubleshooting (T-adapter is
also not provided for the intermediate connector, however, the pin size is larger).
• When replacing the air conditioner wiring harness between connector ACECU of the air
conditioner controller and the intermediate connector, you must replace the entire air
conditioner unit.
a This troubleshooting is performed when failure code [879GKX] is
displayed on the "Electrical Systems" screen of the machine monitor.
See failure code [879GKX].
Defective dual pressure a In certain cases, the dual pressure switch may be operating normally and
1 switch system set to OFF position, therefore, if abnormality is indicated (i.e., switch OFF),
attach a pressure gauge to the air conditioner compressor and check the
refrigerant pressure. (See "Troubleshooting with gauge pressure".)
k Before replacing pressure switch, collect refrigerant.
2. Disconnect the connector AC03 from the air conditioner compressor and
connect a T-adapter to the male side.
Defective air conditioner a Ensure connection of air conditioner compressor ground cable (E).
2 compressor (See "Parts and connectors layout".)
Between connector AC03 (male) (1) and the
Approx. 15
Resistance chassis ground (i.e., air conditioner compressor coil
resistance) z
• Referring to "Testing relays", check sound when compressor clutch relay
is turned ON.
Clicking sound is heard. — A
a When A above is abnormal and B below is abnormal and C is normal (if
the relay is normal), go to cause 4.
Defective compressor 2. Disconnect connector R21.
3 clutch relay (does not 3. Use a wire to short-circuit (3) (white) and (5) (red line on yellow base) of
turn ON) connector R21 (wiring harness side). (This forces the compressor to
operate without using the relay.)
Air is cooled. — B
2. Disconnect connector R21.
Between R21 (male) (1) and (2) (coil Approx. 370
Resistance resistance) C
to 530 z
PC360LC-10 80-69
80 Appendix

a Make sure that result of check of cause 2 is normal (air conditioner
compressor is normal).
Between connector R21 (female) (5) and F01-10
Open circuit in wiring Max. 1 z
4 (When dual pressure switch is ON.)
harness
Between connector R21 (female) (3) and chassis
Approx. 15
Resistance ground z
(Air conditioner compressor coil resistance)
Between F01-14 and AC01 (female) (4) 370 to 530
a Relay coil resistance z
Ground fault in wiring a If the fuse is not blown, skip troubleshooting.

5 2. Disconnect connectors AC03 and R21, and connect a T-adapter to the
circuit) female side of AC03.
Resistance Between AC03 (female) (1) and chassis ground Min. 1 Mz
2. Disconnect connectors AC01, AC02, and R21.
6 a Ensure that test result for cause 2 is normal.
harness
Between wiring harness side (2) of connector R21
Resistance and AC02 (female) (2), (3)*, and (4) Min. 1 Mz

Defective air conditioner 4. Display the air conditioner operation screen on the machine monitor and
7
controller press the A/C switch.
Voltage Between connector R21 (female) (2) and ground Max. 1 V
Defective machine 1. Turn starting switch to ON position.

8 monitor 2. Display the air conditioner operation screen on the machine monitor.
(Defective switch) Press A/C switch. "A/C ON" is displayed.
Defective air conditioner If no failure is found by the above checks, the air conditioner unit may be
9
unit defective.
*: For details of pin 3 of AC02, see "A-1 Troubleshooting for power supply system (Air conditioner does not
operate)".
80-70 PC360LC-10
80 Appendix
Circuit diagram related to compressor and refrigerant system
PC360LC-10 80-71
80 Appendix
A-3 Troubleshooting for blower motor system (No air
comes out or air flow is abnormal)
A-3 Troubleshooting for blower motor system (No air comes out or air
flow is abnormal) (PC220_10-FK3-400-A-00-A)
Failure No air comes out or air flow is abnormal due to blower motor system failure.
• This failure is not checked with self-diagnosis function.
• In cases where the blown-air volume begins to behave in an unpredictable manner after a
certain while during cooling, freezing of the evaporator is a likely cause.
This may be due to the followings.
1. Defective compressor clutch relay (i.e., stuck in ON position) (see item 3 A from
"Troubleshooting for compressor and refrigerant system")
2. Detachment of the evaporator temperature sensor's mounting holder (Replace the air
conditioner unit)
3. Incorrect adjustment of expansion valve (Replace air conditioner unit)
• If air comes out, fuse and motor are normal, and also wiring harness is normal.
• For connectors and power transistor, see "Parts and connectors layout".
Related
information a The power transistor is on the rear side of the air conditioner unit.
• If air comes out but its flow is abnormal in heating mode, replace power transistor. (When
no air comes out, the power transistor may also be defective.)
a The blower motor cannot be replaced unless the air conditioner unit is removed once.
(Although the intermediate connector does not have a T-adapter either, it does have large
pins).
must be replaced.
Defective fuse No. If fuse is blown, circuit probably has ground fault.
1
10 in fuse box F01
Defective power 2. Replace power transistor.
2
transistor a If air comes out and air flow can be adjusted, the original power transistor is
defective.
Breaking of 1. Turn starting switch to OFF position.
harness 2. Disconnect connector AC02.
3 (Wire breakage or 3. Remove fuse No. 10 of fuse box F01.
Resistance Between AC02 (female) (2) and F01-10 Max. 1 z
connectors)
harness 2. Disconnect connectors AC02 and R21.
4 3. Remove fuse No. 10 of F01.
(Contact with GND
Between AC02 (female) (2) or F01-10
circuit) Resistance Max. 1 z
and ground
5 conditioner defective. (Since this is an internal defect, troubleshooting cannot be performed.)
controller
6
conditioner unit
80-72 PC360LC-10
80 Appendix
A-3 Troubleshooting for blower motor system (No air
comes out or air flow is abnormal)
Circuit diagram related to blower motor system
PC360LC-10 80-73
80 Appendix
A-4 Troubleshooting for FRESH/RECIRC air changeover
A-4 Troubleshooting for FRESH/RECIRC air changeover (PC220_10-FKF-400-A-00-A)
Failure • Trouble: FRESH/RECIRC air cannot be selected

• FRESH/RECIRC air changeover is not checked with self-diagnosis function.
• Referring to "Testing FRESH/RECIRC air selector", operate the FRESH/RECIRC air
selector switch and check operation of FRESH/RECIRC air changeover door (damper).
• For connectors, see "Parts and connectors layout".
a The T-adapter is not prepared for the connector.
Related (Although the intermediate connector does not have a T-adapter either, it does have large
information pins).
must be replaced.
• Troubleshooting cannot be performed since the connector portion of the servomotor
cannot be checked while it is installed on machine.
Defective fuse No. If fuse is blown, circuit probably has ground fault.
1
19 in fuse box F01
Breaking of a Connector [5] installed on machine cannot be disconnected since it is on the
harness rear side of the air conditioner unit.
2 (Wire breakage or 1. Turn starting switch to OFF position.
defective contact of 2. Disconnect connector AC02.
connectors) 3. Remove fuse No. 19 of F01.
Resistance Between F01-19 and AC02 (female) (3) Max. 1 z
harness 2. Disconnect connector AC02.
3 3. Remove fuse No. 19 of F01.
(Contact with GND
Between F01-19 and ground, or
circuit) Resistance Max. 1 z
between AC02 (female) (3) and ground
4 conditioner defective. (Since this is an internal defect, troubleshooting cannot be performed.)
controller
5
conditioner unit
2. Display the air conditioner operation screen on the machine monitor.
Defective machine
6 Press FRESH/
monitor
RECIRC air Display of Recirc/Fresh changes.
selector switch.
80-74 PC360LC-10
80 Appendix
A-4 Troubleshooting for FRESH/RECIRC air changeover
Circuit diagram related to FRESH/RECIRC air changeover
PC360LC-10 80-75
80 Appendix
Troubleshooting with gauge pressure
Troubleshooting with gauge pressure (PC220-3840-362-A-00-A)
Perform troubleshooting according to the high and low gauge pressures of the cooling cycle. For details, see
"Connection of service tool".
a The gauge pressure varies largely with the weather condition and operating condition of the machine.
Check the gauge pressure under the pressure measurement conditions.
• Pressure of high-pressure line is too high: Min. approx. 2.5 MPa {25 kg/cm 2}
• Pressure of high-pressure line is too low: Max. approx. 1 MPa {10 kg/cm 2}
• Pressure of low-pressure line is too high: Min. approx. 0.3 MPa {3 kg/cm 2}
• Pressure of low-pressure line is too low: Max. approx. 0.05 MPa {0.5 kg/cm 2}
a Dual pressure switch turns "OFF" to protect the air conditioner circuit if the pressure of the high-pressure
or low-pressure line is abnormal.
[Measurement condition for pressure]
Item Condition value
Ambient temperature 25 to 50 °C
Engine speed 1,500 rpm
Air conditioner switch ON
Fan switch HI
Set temperature Cool-Max
• Dual pressure switch
a The switch is normally "ON", and becomes "OFF" when it detects abnormal pressure for compressor
operation.
LA: 0.20 MPa {2 kg/cm2}

LB: 0.02 MPa {0.2 kg/cm2}
HA: 3.14 MPa {32 kg/cm2}
HB: 0.59 MPa {6 kg/cm2}
80-76 PC360LC-10
80 Appendix
Indicated gauge pressure Cause Check method Remedy

Air conditioner cycle is operating normally.
If any problem (poor cooling) is recognized, the cause
is in other system.
Pressure is normal Pressure of high-pressure line: Approx. 1.5 to -1.7 ―
MPa {15 to 17 kg/cm2}
Pressure of low-pressure line: Approx. 0.13 to 0.2
MPa {1.3 to 2.0 kg/cm2}
Collect refrigerant, then fill
Bubbles can be seen
Insufficient refrigerant up with proper quantity of
through sight glass. *1, *3
refrigerant again. *2
Temperature difference is
recognized between inlet
Clogging of receiver drier and outlet pipes of Replace *2
receiver drier.
Tank is frosty.
Clogging of expansion Expansion valve is frosty. Clean or replace *2
valve
Gas leakage at
<Pressure of both high- Low-pressure line gauge Replace *2
thermoprobe of expansion
pressure and low- reads vacuum.
valve
pressure lines are too
Evaporator is frozen.
low>
Flow rate of refrigerant is Repair or replace
Low-pressure line gauge Defective evaporator
reduced due to freezing.
reads vacuum temperature sensor or Replace receiver drier.
defective contact of (If air conditioner is set to
sensor (coming off of Cool Max. and HI fan
up with proper quantity of
mounting clip) speed modes, later its
cooling performance
lowers.)
Piping between receiver
drier and compressor is
clogged or crushed.
Clogged or crushed piping Clean or replace *2
If clogged completely, low-
pressure line gauge reads
vacuum
Filling of too much
Connect gauge manifold. up with proper quantity of
refrigerant
Check condenser for dirt, Clean condenser, repair
Defective cooling of fins for clogging or fins, or repair or replace
condenser crushing, and cooling fan cooling fan *2
<Pressure of both high- for defective rotation.
pressure and low- Defective adjustment of
pressure lines are too expansion valve Bubbles can be seen
high> Replace *2
(Valve is excessively through sight glass. *3
opened.)
Evacuate air from air
Air sucked in cooling Bubbles can be seen conditioner and then fill up
cycle parts through sight glass. *3 with proper quantity of
PC360LC-10 80-77
80 Appendix
Indicated gauge pressure Cause Check method Remedy

<Pressure of high- Piping between Remarkable temperature Clean inside of cooling
pressure line is too high compressor and difference is recognized cycle parts or replace
and that of low-pressure condenser is Clogged or across clogged part. them.*2
line is too low> crushed.
Pressures of high-
pressure and low-
<Pressure of high- pressure lines are almost
Defective compressor
pressure line is too low the same while
(compression trouble of Replace *2
and that of low-pressure compressor is running.
compressor)
line is too high>
Compressor has seized
and is extremely hot.
*1: If refrigerant leaks, compressor oil in the air conditioner circuit always leaks, too. So perform the check
mainly on pipe joints and dirty parts with oil.
*2:
k When replacing cooling cycle parts, be sure to collect refrigerant. For details, see "Precautions for
refrigerant". After replacing parts, fill the air conditioner circuit with refrigerant.
*3: Sight glass is on the air conditioner hose near the condenser.
80-78 PC360LC-10
80 Appendix
Connection of service tool
Connection of service tool (PC400-S100-730-P-00-A)
k Place the machine on a level surface, lower the work equipment to the ground so that it is stable,
and stop the engine.
k Turn the battery disconnect switch to OFF position, and remove the key.
a Following service tool kit is used for work with refrigerant R134a.
Symbol Part No. Part name
X 799-703-1200 Service tool kit
a Use the service tool kit for R134a.

Service tool kit X
(1): Gauge manifold
(2): Red high-pressure line charging hose
(3): Blue low-pressure line charging hose
(4): Large diameter quick joint (for high-pressure line)
(5): Small diameter quick joint (for low-pressure line)
(a): Note that the threads are coarse and the hoses are relatively easy to loosen.
Connect the gauge manifold, hoses and other service tools according to the following procedure.
1. Close high-pressure line valve (6) and low-pressure line valve (7) of gauge manifold (1).
2. Connect red high-pressure line charging hose (2) to the gauge manifold (1) (HI side) and blue low-
pressure line charging hose (3) to the gauge manifold (1) (LO side).
3. Connect quick joints (4) and (5) to each hose.
4. Connect quick joints (4) and (5) to service valves (8) and (9) of high- and low-pressure piping respectively.
PC360LC-10 80-79
80 Appendix
Connection of service tool
A: From operator's cab

B: To condenser
80-80 PC360LC-10
80 Appendix
Precautions for disconnecting and connecting air
conditioner piping
Precautions for disconnecting and connecting air conditioner

piping (PC300-K5B0-924-K-00-A)
Precautions for disconnecting
k Collect the refrigerant (Air conditioner gas: R134a) from air conditioner circuit before
disconnecting air conditioner hose to replace air conditioner unit, air conditioner compressor or
receiver drier and so on.
a Ask a qualified person for collecting, adding and filling operation of refrigerant (R134a).
a Never release the refrigerant (R134a) to the atmosphere.
k If refrigerant gas (R134a) gets in your eyes, you may lose your sight. And if it touches your skin,
you may suffer from frostbite. Accordingly, put on protective eyeglasses, gloves and working cloth
with long sleeves while collecting the refrigerant or filling the air conditioner circuit with the
refrigerant.
• When loosening the air conditioner hose nuts after collecting the refrigerant, be sure to use 2 wrenches.
Use one wrench to fix and use the other one to loosen the nuts.
Precautions for connecting
• When connecting piping, apply compressor oil (ND-OIL8) for R134a to its O-rings. (See item 4 of
"Handling compressor oil")
Do not apply oil to the threads of a bolt, nut or union, however.
• Once an O-ring is used, it is deformed and deteriorated. Accordingly, do not reuse it. When removing it,
use a soft tool (such as a toothpick) so that the piping will not be damaged.
• Push in each pipe to the stopper and tighten the bolt or nut fully with your fingers.
• Be sure to use two wrenches to tighten each nut. Use one wrench to fix and tighten the nut with the other
wrench to the specified torque (Use a torque wrench for tightening).
Table of tightening torque for refrigerant pipe joint.

Thread size Tightening torque Nm {kgm}
3.9 to 6.9 {0.4 to 0.7} (Receiver drier)
M6 x 1.0
8 to 12 {0.8 to 1.2} (Air conditioner unit and compressor)
M16 x 1.5 12 to 15 (1.2 to 1.5)
M22 x 1.5 20 to 25 {2.0 to 2.5}
M24 x 1.5 30 to 35 {3.1 to 3.6}
PC360LC-10 80-81
80 Appendix
Precautions for disconnecting and connecting air
conditioner piping
1. Engine
2. Compressor
3. Condenser
4. Receiver drier
80-82 PC360LC-10
80 Appendix
Handling of compressor oil
Handling of compressor oil (PC300-K594-212-K-00-A)

1. Compressor oil management (DENSO: ND-OIL8 for R134a)
Although compressor oil differs from engine oil in that it does not need regular checking or filling, the following
types of problem can occur if the amount in the system is too high or too low.
Condition Content
Insufficiency of oil Lubrication trouble and seizure of compressor
Cooling trouble (Excessive oil stick to parts and lower heat exchange
Excess of oil performance)
Accordingly, compressor oil must be filled to the specified level, similarly to refrigerant.
2. Filling compressor oil

k Refrigerant is potentially hazardous to health and to the environment. Before disconnecting air
conditioner hoses, therefore, refrigerant should be collected in accordance with "Precautions for
connecting air conditioner piping."
a If oil for CFC-12 (R-12) is used, lubrication trouble will occur and the compressor may be broken or seized.
Be sure to use an oil suitable for R134a (DENSO: ND-OIL8).
a Oil for use with R134a is extremely hygroscopic, and therefore, the cap must be immediately closed after
use to limit contact with air.
Store the oil can in a dry and ventilated place.
a Precautions for using oil
Do not allow oil for use with R134a to come into contact with acrylic plastic or polystyrene surfaces (except
a baked finish) as it may dissolve these plastics.
Check compressor oil in the following cases, and then add new oil if necessary.
• When much refrigerant is discharged because of leakage.
• When the compressor is troubled and replaced.
(See 3 below)
• When a cycle parts such as condenser, receiver drier, evaporator unit, etc. is replaced.
• Quantity of oil to be added when cycle part is replaced
Air conditioner part Quantity to be added (cc)
Air conditioner unit, evaporator Approx. 40
Condenser Approx. 40
Receiver drier Approx. 20
Hose (between M24 joint and cab) Approx. 20
Hose (compressor to M24 joint) Approx. 10
Hose (compressor to M22 joint) Approx. 30
Hose (between M22 joint and condenser) Approx. 10
Hose (Condenser – Receiver dryer) Approx. 5
Hose (Cab – Receiver drier) Approx. 20
PC360LC-10 80-83
80 Appendix
Handling of compressor oil
3. Replacement of compressor
• In case of compressor seizure or breakage.
Metal chips will circulate through the air conditioner circuit and contaminate the compressor oil extremely.
In this case, flush the air conditioner circuit and replace the compressor and receiver drier.
The compressor oil is removed from the air conditioner circuit by flushing. Accordingly, install a new
compressor with the oil of the specified quantity (180 cc) filled in it.
• Other cases
a New compressor contains compressor oil of 180 cc in it.
1. Prepare an oil container and drain oil from the old compressor.
2. Measure the quantity of the drained oil with a measuring cylinder, and note the quantity or mark the level.
3. Drain below-mentioned quantity of oil from the new compressor.

Quantity to be drained = 180 cc - "Noted quantity"
Example: If 30 cc was drained from the removed compressor, the quantity to be drained from the new
compressor would be 150 cc (i.e., 180 - 30 cc).
4. Applying compressor oil to O-rings

Whenever connecting piping or hoses, the compressor oil (ND-OIL8) must be applied to O-rings in order to
prevent the leakage of refrigerant.
80-84 PC360LC-10
SHOP MANUAL
HYDRAULIC EXCAVATOR
PC360LC-10
Model Serial Number
PC360LC-10 70001 and up
90 Diagrams and drawings

10 90 Diagrams and drawings
PC360LC-10 90-1
Table of contents

90 Diagrams and drawings................................................................................................................. 90-1
Hydraulic circuit diagram ............................................................................................................. 90-3
Symbols in hydraulic circuit diagram ...................................................................................... 90-3
Hydraulic circuit diagram....................................................................................................... 90-7
Electric circuit diagram ................................................................................................................ 90-9
Symbols in electric circuit diagram ......................................................................................... 90-9
Electric circuit diagram........................................................................................................ 90-13
Electric circuit diagram for air conditioner unit ....................................................................... 90-25
90-2 PC360LC-10
Symbols in hydraulic circuit diagram
Hydraulic circuit diagram (ALL-C000-001-K-90-A)
Symbols in hydraulic circuit diagram (PC220-0000-007-K-00-A)
(Rev. 2010/03)
PC360LC-10 90-3
90-4 PC360LC-10
PC360LC-10 90-5
90-6 PC360LC-10
Hydraulic circuit diagram Hydraulic circuit diagram 1
PC360LC-10
PC360LC-10
a The illustration shows PC360LC-10.
a This figure covers the equipment and devices that are unavailable as optional items in some areas.
PC360LC-10
90-7
Symbols in electric circuit diagram
Electric circuit diagram (ALL-0000-001-K-90-A)
Symbols in electric circuit diagram (PC220-0000-008-K-00-A)
(Rev. 2010/03)
PC360LC-10 90-9
90-10 PC360LC-10
PC360LC-10 90-11
90-12 PC360LC-10
Electrical circuit diagram (1/6) Electrical circuit diagram (1/6) 1
PC360LC-10
PC360LC-10
PC360LC-10 90-13
PC360LC-10
PC360LC-10
PC360LC-10 90-15
PC360LC-10
PC360LC-10
PC360LC-10 90-17
PC360LC-10
PC360LC-10
PC360LC-10 90-19
PC360LC-10
PC360LC-10
PC360LC-10 90-21
PC360LC-10
PC360LC-10
PC360LC-10 90-23
Air conditioner electrical circuit diagram Air conditioner electrical circuit diagram 1
PC360LC-10
PC360LC-10
a In the drawing, full line shows air conditioner wiring harness, dashed lines show the cab and chassis wiring harness. (For the details of cab harness and chassis harness, see "Electrical circuit diagram".)
a In the drawing, dot and dash line shows machine monitor wiring, which consists of twisted lines (AVS 0.5 x 2, pitch 45 mm or less).
PC360LC-10 90-25
INDEX
INDEX
2nd-line attachment PPC valve ...................... 60-48 D

Disassembly and assembly of carrier roller ... 50-158
A Disassembly and assembly of center swivel
joint.......................................................... 50-169
A-2 Troubleshooting for compressor and
Disassembly and assembly of control valve .. 50-183
refrigerant system (Air is not cooled) ............. 80-69
Disassembly and assembly of final drive....... 50-127
A-1 Troubleshooting for power supply system
Disassembly and assembly of idler............... 50-151
(Air conditioner does not operate) ................. 80-67
Disassembly and assembly of idler cushion .. 50-154
A-3 Troubleshooting for blower motor system
Disassembly and assembly of KDPF ............ 50-109
(No air comes out or air flow is abnormal) ...... 80-72
Disassembly and assembly of swing
A-4 Troubleshooting for FRESH/RECIRC air
machinery ................................................ 50-138
changeover ................................................ 80-74
Disassembly and assembly of track roller ..... 50-156
Accumulator ............................................... 10-186
Disassembly and assembly of travel PPC
Adjusting mirrors........................................... 30-92
valve ........................................................ 50-190
Adjusting play of work equipment and swing
Disassembly and assembly of work equipment
PPC valves ................................................ 30-82
cylinder .................................................... 50-198
Adjusting rearview camera angle ................. 30-161
Disassembly and assembly of work equipment
Air conditioner component ............................... 80-4
PPC valve ................................................ 50-188
Air conditioner controller ................................ 80-18
Dual pressure switch..................................... 80-17
Air conditioner unit ........................................ 80-10
Attachment circuit selector valve ........ 10-181, 60-51
E
B E-1 Engine does not start (Engine does not
crank) ...................................................... 40-566
Bleeding air from fuel system ......................... 30-44
E-2 Manual preheating does not work........... 40-572
Bleeding air from hydraulic circuit ................... 30-88
E-3 Automatic preheating system does not
work......................................................... 40-575
C E-4 While preheating is working, preheating
monitor does not light up............................ 40-577
Cab mount and cab tipping stopper .............. 10-190 E-5 When starting switch is turned to ON
Carrier roller ................................................. 60-18 position, machine monitor displays nothing.. 40-579
Center swivel joint....................................... 10-184 E-6 While starting switch is turned to ON
Checking and adjusting air conditioner position (with engine stopped), engine oil
compressor belt tension............................... 30-48 level monitor lights up in yellow .................. 40-582
Checking cab tipping stopper......................... 30-91 E-7 While starting switch is turned to ON
Checks before troubleshooting....................... 40-13 position (with engine stopped), radiator
Circuit diagram and arrangement of connector coolant level monitor lights up in yellow ....... 40-583
pins ........................................................... 80-26 E-8 Engine coolant temperature monitor lights
Classification and procedure for up in white while engine is running.............. 40-584
troubleshooting ........................................... 40-41 E-9 Hydraulic oil temperature monitor lights up
CLSS........................................................... 10-44 in white while engine is running .................. 40-585
Coating materials list....................................... 50-6 E-10 Charge level monitor lights up in red while
Compressor ................................................. 80-19 engine is running....................................... 40-586
Condenser ................................................... 80-20 E-11 Fuel level monitor lights up in red while
Configuration and function of refrigeration engine is running....................................... 40-587
cycle ............................................................ 80-7 E-12 Air cleaner clogging monitor lights up in
Connection of service tool ............................. 80-79 yellow while engine is running .................... 40-588
Connector contact identification ..................... 40-62 E-13 Engine coolant temperature monitor
Connector list and layout ............................... 40-51 lights up in red while engine is running ........ 40-589
Control valve ...................................... 10-74, 60-24 E-14 Hydraulic oil temperature monitor lights
Conversion table .......................................... 00-60 up in red while engine is running................. 40-590
Cooling system.....................................10-28, 60-4 E-15 Engine oil pressure monitor lights up in
red while engine is running......................... 40-591
E-16 Fuel gauge display does not move from
minimum or maximum ............................... 40-592
PC360LC-10 1
INDEX
E-17 Display of fuel gauge differs from actual E-45 Wiper does not operate when wiper
fuel level................................................... 40-593 switch is operated ..................................... 40-629
E-18 Engine coolant temperature gauge E-46 When window washer switch is operated,
display does not move from minimum or window washer does not operate................ 40-631
maximum ................................................. 40-594 E-47 Boom LOWER indicator is not displayed
E-19 Display of engine coolant temperature properly with monitoring function ................ 40-632
gauge differs from actual coolant temperature ...40- E-48 Arm OUT indicator is not displayed
595 properly with monitoring function ................ 40-633
E-20 Hydraulic oil temperature gauge display E-49 Arm IN indicator is not displayed properly
does not move from minimum or maximum . 40-596 with monitoring function ............................. 40-634
E-21 Display of hydraulic oil temperature E-50 Boom RAISE indicator is not displayed
gauge differs from actual oil temperature..... 40-598 properly with monitoring function ................ 40-635
E-22 Machine monitor does not display E-51 Bucket CURL indicator is not displayed
partially .................................................... 40-599 properly with monitoring function ................ 40-636
E-23 Function switch does not operate ......... 40-600 E-52 Bucket DUMP indicator is not displayed
E-24 Automatic warm-up system does not properly with monitoring function ................ 40-637
work (in cold weather)................................ 40-601 E-53 Swing indication is not displayed properly
E-25 When auto-decelerator switch is with monitoring function ............................. 40-638
operated, auto-decelerator monitor does not E-54 Travel indication is not displayed properly
light up or does not go off........................... 40-602 with monitoring function ............................. 40-639
E-26 Auto-decelerator is not operated or E-55 Service indication is not displayed
canceled with lever.................................... 40-603 properly with monitoring function ................ 40-640
E-27 When working mode switch is operated, E-56 Attachment circuit is not switched ......... 40-642
working mode selection screen is not E-57 KOMTRAX system does not operate
displayed.................................................. 40-604 properly.................................................... 40-643
E-28 When working mode is changed, setting E-58 Machine push-up function is not canceled ...40-
of engine and hydraulic pump is not changed ....40- 644
605 E-59 Machine push-up function does not work ....40-
E-29 When travel speed switch is operated, 646
travel speed monitor does not change......... 40-606 EGR cooler .................................................. 10-18
E-30 When travel speed selection is changed, EGR system circuit diagram .......................... 10-14
actual travel speed does not change........... 40-607 EGR system piping drawing........................... 10-12
E-31 Alarm buzzer cannot be canceled......... 40-608 EGR valve ................................................... 10-16
E-32 When starting switch is turned OFF, Electric circuit diagram .................................. 90-13
service meter is not displayed .................... 40-609 Electric circuit diagram for air conditioner unit .. 90-25
E-33 Machine monitor cannot be set in service Electrical control system.............................. 10-192
mode ....................................................... 40-610 Engine controller......................................... 10-227
E-34 Any of work equipment, swing and travel Engine mount ................................................. 60-3
does not work ........................................... 40-611 Engine related parts ........................................ 10-3
E-35 Any of work equipment, swing and travel Explanation of terms for maintenance standard ...00-
cannot be locked....................................... 40-613 23
E-36 Upper structure does not swing while
swing brake cancel switch is set to CANCEL
position .................................................... 40-615
F
E-37 Swing brake does not operate while Failure code [879AKA] A/C Inner sensor Open
swing brake cancel switch is set to NORMAL Circuit ........................................................ 80-54
position .................................................... 40-617 Failure code [879AKA] A/C Inner Sensor Open
E-38 One-touch power maximizing function Circuit ...................................................... 40-121
does not work properly or pilot monitor is not Failure code [879AKB] A/C Inner sensor Short
displayed.................................................. 40-619 Circuit ........................................................ 80-55
E-39 One-touch power maximizing function Failure code [879AKB] A/C Inner Sensor Short
cannot be canceled ................................... 40-621 Circuit ...................................................... 40-122
E-40 Alarm does not sound during travel....... 40-622 Failure code [879BKA] A/C Outer Sensor
E-41 Alarm does not stop sounding while Open Circuit ............................................. 40-123
machine is stopped ................................... 40-624 Failure code [879BKB] A/C Outer Sensor Short
E-42 Horn does not sound ........................... 40-625 Circuit ...................................................... 40-124
E-43 Horn does not stop sounding ............... 40-627 Failure code [879CKA] Ventilating sensor
E-44 When wiper switch is operated, wiper Open Circuit ............................................... 80-60
monitor does not light up or go off ............... 40-628
2 PC360LC-10
INDEX
Failure code [879CKA] Ventilating Sensor Failure code [CA1695] Sens 5 Supply Volt
Open Circuit ............................................. 40-125 High Error................................................. 40-254
Failure code [879CKB] Ventilating sensor Failure code [CA1696] Sens 5 Supply Volt Low
Short Circuit ............................................... 80-61 Error ........................................................ 40-255
Failure code [879CKB] Ventilating Sensor Failure code [CA1843] Crankcase Press Sens
Short Circuit ............................................. 40-126 High Error................................................. 40-257
Failure code [879DKZ] Sunlight Sensor Open Failure code [CA1844] Crankcase Press
Or Short Circuit ......................................... 40-127 Sensor Low Error ...................................... 40-259
Failure code [879EMC] Ventilating Damper Failure code [CA187] Sensor 2 Supply Volt
Abnormality ................................................ 80-64 Low Error ................................................. 40-165
Failure code [879EMC] Ventilation Damper Failure code [CA1879] KDPF Delta Pressure
Abnormality .............................................. 40-128 Sensor High Error ..................................... 40-261
Failure code [879FMC] Air Mix Damper Failure code [CA1881] KDPF Delta Pressure
Abnormality .................................... 40-129, 80-65 Sensor Low Error ...................................... 40-263
Failure code [879GKX] Refrigerant Failure code [CA1883] KDPF Delta P Sens In
Abnormality .............................................. 40-130 Range Error.............................................. 40-265
Failure code [989L00] Engine Controller Lock Failure code [CA1921] KDPF Soot Load High
Caution 1 ................................................. 40-131 Error 1...................................................... 40-268
Failure code [989M00] Engine Controller Lock Failure code [CA1922] KDPF Soot Load High
Caution 2 ................................................. 40-132 Error 2...................................................... 40-271
Failure code [989N00] Engine Controller Lock Failure code [CA1942] Crankcase Press Sens
Caution 3 ................................................. 40-133 In Range Error .......................................... 40-276
Failure code [A1U0N3] HC Desorb Request 1 .....40- Failure code [CA1993] KDPF Delta Pressure
134 Low Error ................................................. 40-277
Failure code [A1U0N4] HC Desorb Request 2 .....40- Failure code [CA2185] Throt Sens Sup Volt
136 High Error................................................. 40-280
Failure code [AA10NX] Air Cleaner Clogging. 40-138 Failure code [CA2186] Throt Sens Sup Volt
Failure code [AB00KE] Charge Voltage Low . 40-140 Low Error ................................................. 40-282
Failure code [B@BAZG]Eng Oil Press Low... 40-142 Failure code [CA221] Ambient Press Sensor
Failure code [B@BAZK] Eng Oil Level Low ... 40-143 High Error................................................. 40-167
Failure code [B@BCNS] Eng Water Overheat .....40- Failure code [CA222] Ambient Press Sensor
144 Low Error ................................................. 40-169
Failure code [B@BCZK] Eng Water Level Low ....40- Failure code [CA2249] Rail Press Very Low
145 Error 2...................................................... 40-284
Failure code [B@HANS] Hyd Oil Overheat.... 40-147 Failure code [CA2265] Fuel Feed Pump Open
Failure code [CA1117] Persistent Data Lost Error ........................................................ 40-285
Error ........................................................ 40-248 Failure code [CA2266] Fuel Feed Pump Short
Failure code [CA115] Eng Ne and Bkup Speed Error ........................................................ 40-287
Sens Error ................................................ 40-148 Failure code [CA227] Sensor 2 Supply Volt
Failure code [CA122] Chg Air Press Sensor High Error................................................. 40-171
High Error................................................. 40-149 Failure code [CA2271] EGR Valve Pos Sens
Failure code [CA123] Chg Air Press Sensor High Error................................................. 40-289
Low Error ................................................. 40-151 Failure code [CA2272] EGR Valve Pos Sens
Failure code [CA131] Throttle Sensor High Low Error ................................................. 40-291
Error ........................................................ 40-153 Failure code [CA2288] Turbo Speed High Error
Failure code [CA132] Throttle Sensor Low 1.............................................................. 40-294
Error ........................................................ 40-155 Failure code [CA2311] IMV Solenoid Error .... 40-295
Failure code [CA144] Coolant Temp Sens High Failure code [CA234] Eng Overspeed........... 40-172
Error ........................................................ 40-157 Failure code [CA2349] EGR Valve Solenoid
Failure code [CA145] Coolant Temp Sens Low Open Error ............................................... 40-296
Error ........................................................ 40-159 Failure code [CA2353] EGR Valve Solenoid
Failure code [CA153] Chg Air Temp Sensor Short Error................................................ 40-298
High Error................................................. 40-161 Failure code [CA2357] EGR Valve Servo Error ....40-
Failure code [CA154] Chg Air Temp Sensor 300
Low Error ................................................. 40-163 Failure code [CA2373] Exhaust Manifold Press
Failure code [CA1664] KDOC Malfunction .... 40-249 Sens High Error ........................................ 40-301
Failure code [CA1691] Regeneration Failure code [CA2374] Exhaust Manifold Press
Ineffective................................................. 40-251 Sens Low Error ......................................... 40-303
PC360LC-10 3
INDEX
Failure code [CA2375] EGR Orifice Temp Sens Failure code [CA3256] KDPF Outlet Temp
High Error................................................. 40-305 High Error 1 .............................................. 40-351
Failure code [CA2376] EGR Orifice Temp Sens Failure code [CA331] Inj #2(L#2) Open/Short
Low Error ................................................. 40-307 Error ........................................................ 40-189
Failure code [CA238] Ne Speed Sensor Failure code [CA3311] KDOC Outlet Temp
Supply Volt Error ....................................... 40-173 High Error 2 .............................................. 40-354
Failure code [CA2381] KVGT Pos Sens High Failure code [CA3312] KDPF Outlet Temp
Error ........................................................ 40-309 High Error 2 .............................................. 40-357
Failure code [CA2382] KVGT Pos Sens Low Failure code [CA3313] KDOC Inlet Temp
Error ........................................................ 40-311 Sensor Low Error ...................................... 40-360
Failure code [CA2383] KVGT Solenoid Open Failure code [CA3314] KDOC Inlet Temp
Error ........................................................ 40-314 Sensor High Error ..................................... 40-363
Failure code [CA2386] KVGT Solenoid Short Failure code [CA3315] KDOC Inlet Temp Sens
Error ........................................................ 40-316 In Range Error .......................................... 40-367
Failure code [CA2387] KVGT Servo Error ..... 40-318 Failure code [CA3316] KDOC Outlet Temp
Failure code [CA239] Ne Speed Sens Supply Sens Low Error ......................................... 40-371
Volt High Error .......................................... 40-174 Failure code [CA3317] KDOC Outlet Temp
Failure code [CA2554] Exh Manifold Press Sens High Error ........................................ 40-374
Sens In Range Error.................................. 40-319 Failure code [CA3318] KDOC Outlet Temp
Failure code [CA2555] Grid Htr Relay Open Sens In Range Error.................................. 40-378
Circuit Error .............................................. 40-320 Failure code [CA3319] KDPF Outlet Temp
Failure code [CA2556] Grid Htr Relay Short Sens High Error ........................................ 40-382
Circuit Error .............................................. 40-322 Failure code [CA332] Inj #4(L#4) Open/Short
Failure code [CA2637] KDOC Face Plugging 40-324 Error ........................................................ 40-191
Failure code [CA2639] Manual Stationary Failure code [CA3321] KDPF Outlet Temp
Regeneration Request............................... 40-326 Sens Low Error ......................................... 40-386
Failure code [CA271] IMV/PCV1 Short Error . 40-175 Failure code [CA3322] KDPF Outlet Temp
Failure code [CA272] IMV/PCV1 Open Error . 40-177 Sens In Range Error Failure code [CA3322]
Failure code [CA281] Pump Press Balance KDPF Outlet Temp Sens In Range Error ..... 40-389
Error ........................................................ 40-179 Failure code [CA3419] Mass Air Flow Sensor
Failure code [CA295] Ambient Pressure Sup Volt High Error.................................... 40-393
Sensor In Range Error............................... 40-180 Failure code [CA3421] Mass Air Flow Sensor
Failure code [CA2961] EGR Orifice Temp High Sup Volt Low Error .................................... 40-395
Error 1...................................................... 40-329 Failure code [CA343] ECM Critical Internal
Failure code [CA2973] Chg Air Press Sensor Failure ..................................................... 40-193
In Range Error .......................................... 40-330 Failure code [CA351] Injectors Drive Circuit
Failure code [CA3133] KDPF Outlet Press Error ........................................................ 40-194
Sens High Error ........................................ 40-331 Failure code [CA352] Sensor 1 Supply Volt
Failure code [CA3134] KDPF Outlet Press Low Error ................................................. 40-195
Sens Low Error ......................................... 40-333 Failure code [CA356] Mass Air Flow Sensor
Failure code [CA3135] KDPF Outlet Press High Error................................................. 40-197
Sens In Range Error.................................. 40-335 Failure code [CA357] Mass Air Flow Sensor
Failure code [CA322] Inj #1(L#1) Open/Short Low Error ................................................. 40-199
Error ........................................................ 40-181 Failure code [CA3741] Rail Press Valve Trip
Failure code [CA323] Inj #5(L#5) Open/Short Error ........................................................ 40-397
Error ........................................................ 40-183 Failure code [CA386] Sensor 1 Supply Volt
Failure code [CA324] Inj #3(L#3) Open/Short High Error................................................. 40-201
Error ........................................................ 40-185 Failure code [CA428] Water in Fuel Sensor
Failure code [CA325] Inj #6(L#6) Open/Short High Error................................................. 40-202
Error ........................................................ 40-187 Failure code [CA429] Water in Fuel Sensor
Failure code [CA3251] KDOC Inlet Temp High Low Error ................................................. 40-204
Error ........................................................ 40-339 Failure code [CA435] Eng Oil Press Sw Error......40-
Failure code [CA3253] KDOC Temp Error - 206
Non Regeneration ..................................... 40-342 Failure code [CA441] Battery Voltage Low
Failure code [CA3254] KDOC Outlet Temp Error ........................................................ 40-207
High Error 1 .............................................. 40-345 Failure code [CA442] Battery Voltage High
Failure code [CA3255] KDPF Temp Error - Non Error ........................................................ 40-209
Regeneration............................................ 40-348 Failure code [CA449] Rail Press Very High
Error ........................................................ 40-210
4 PC360LC-10
INDEX
Failure code [CA451] Rail Press Sensor High Failure code [DA2LKB] System Operating
Error ........................................................ 40-212 Lamp Short Circuit (Pump Con).................. 40-419
Failure code [CA452] Rail Press Sensor Low Failure code [DA2QKR] CAN2 Discon ( Pump
Error ........................................................ 40-214 Con) ........................................................ 40-420
Failure code [CA488] Chg Air Temp High Failure code [DA2RKR] CAN1 Discon ( Pump
Torque Derate........................................... 40-216 Con) ........................................................ 40-423
Failure code [CA515] Rail Press Sens Sup Volt Failure code [DAF0MB] Monitor ROM
High Error................................................. 40-217 Abnormality .............................................. 40-424
Failure code [CA516] Rail Press Sens Sup Volt Failure code [DAF0MC] Monitor Error ........... 40-425
Low Error ................................................. 40-219 Failure code [DAF8KB] Camera Power Supply
Failure code [CA553] Rail Press High Error... 40-221 Short Circuit ............................................. 40-426
Failure code [CA555] Crankcase Press High Failure code [DAF9KQ] Model Selection
Error 2...................................................... 40-222 Abnormality .............................................. 40-428
Failure code [CA556] Crankcase Press High Failure code [DAFGMC] GPS Module Error .. 40-429
Error 2...................................................... 40-223 Failure code [DAFLKA] Operating Lamp Open
Failure code [CA559] Rail Pump Press Low Circuit(Monitor) ......................................... 40-430
Error ........................................................ 40-224 Failure code [DAFLKB] System Operating
Failure code [CA595] Turbo Speed High Error Lamp Short Circuit (Monitor) ...................... 40-432
2.............................................................. 40-228 Failure code [DAFQKR] CAN2 Discon
Failure code [CA687] Turbo Speed Low Error .....40- (Monitor) .................................................. 40-433
229 Failure code [DAZ9KQ] AC Model Selection
Failure code [CA689] Eng Ne Speed Sensor Abnormality .............................................. 40-434
Error ........................................................ 40-231 Failure code [DAZQKR] CAN2 Discon (AC) .. 40-435
Failure code [CA691] Intake Air Temp Sens Failure code [DB2QKR] CAN2 Discon (Engine
High Error................................................. 40-235 Con) ........................................................ 40-440
Failure code [CA692] Intake Air Temp Sens Failure code [DB2RKR] CAN1 Discon (Engine
Low Error ................................................. 40-237 Con) ........................................................ 40-445
Failure code [CA697] ECM Internal Temp Failure code [DGH2KB] Hyd Oil Sensor Short
Sensor High Error ..................................... 40-239 Circuit ...................................................... 40-449
Failure code [CA698] ECM Int Temp Sensor Failure code [DHA4KA] Air Cleaner Clogging
Low Error ................................................. 40-240 Sensor Open Circuit .................................. 40-451
Failure code [CA731] Eng Bkup Speed Sens Failure code [DHPAMA] Pump Press Sensor
Phase Error .............................................. 40-241 Abnormality .............................................. 40-453
Failure code [CA778] Eng Bkup Speed Sensor Failure code [DHPBMA] R Pump Press Sensor
Error ........................................................ 40-243 Abnormality .............................................. 40-456
Failure code [D110KB] Battery Relay Drive S/C...40- Failure code [DHS3MA] Arm IN PPC Sen.
398 Abnormality .............................................. 40-459
Failure code [D19JKZ] Personal Code Relay Failure code [DHS4MA] Bucket CURL PPC
Abnormality .............................................. 40-400 Press Sensor Abnormality ......................... 40-461
Failure code [D811MC] KOMTRAX Error ...... 40-403 Failure code [DHS8MA] Boom RAISE PPC
Failure code [D862KA] GPS Antenna Open Press Sensor Abnormality ......................... 40-464
Circuit ...................................................... 40-404 Failure code [DHS9MA] Boom LOWER Press
Failure code [D8ALKA] System Operating Sensor Abnormality................................... 40-467
Lamp Disconnection (KOMTRAX) .............. 40-405 Failure code [DHSAMA] Swing RH PPC Press
Failure code [D8ALKB] System Operating Sensor Abnomality .................................... 40-470
Lamp Short Circuit (KOMTRAX) ................. 40-407 Failure code [DHSBMA] Swing LH PPC Press
Failure code [D8AQKR] CAN2 Discon Sensor Abnomality .................................... 40-473
(KOMTRAX) ............................................. 40-408 Failure code [DHSCMA] Arm OUT PPC Press
Failure code [DA20MC] Pump Controller Sensor Abnormality................................... 40-476
Malfunction............................................... 40-409 Failure code [DHSDMA] Bucket Dump PPC
Failure code [DA22KK] Pump Solenoid Power Press Sensor Abnormality ......................... 40-479
Low Error ................................................. 40-410 Failure code [DHSFMA] Travel FW L PPC
Failure code [DA25KP] 5V Sensor1 Power Press Sensor Abnormality ......................... 40-482
Abnormality .............................................. 40-412 Failure code [DHSGMA] Travel FW R PPC
Failure code [DA29KQ] Model Selection Press Sensor Abnormality ......................... 40-485
Abnormality .............................................. 40-415 Failure code [DHSHMA] Travel BW L PPC
Failure code [DA2LKA] System Operating Press Sensor Abnormality ......................... 40-488
Lamp Disconnection (Pump Con) ............... 40-417 Failure code [DHSJMA] Travel BW R PPC
Press Sensor Abnormality ......................... 40-491
PC360LC-10 5
INDEX
Failure code [DKR0MA] F pump S/P sensor Failure code [DXE6KA] Merge-divider LS Sol
Abnormality .............................................. 40-494 Open Circuit ............................................. 40-552
Failure code [DKR1MA] R pump S/P sensor Failure code [DXE6KB] Merge-divider LS Sol
Abnormality .............................................. 40-496 Short Circuit ............................................. 40-554
Failure code [DR21KX] Camera 2 Picture Rev. Failure code [DY20KA] Wiper Working
Drive Abnormality...................................... 40-498 Abnormality .............................................. 40-556
Failure code [DR31KX] Camera 3 Picture Rev. Failure code [DY20MA] Wiper Parking
Drive Abnormality...................................... 40-500 Abnormality .............................................. 40-558
Failure code [DV20KB] Travel Alarm Short Failure code [DY2CKB] Washer Drive Short
Circuit ...................................................... 40-502 Circuit ...................................................... 40-560
Failure code [DW43KA] Travel Speed Sol Failure code [DY2DKB] Wiper Drive (For)
Open Circuit ............................................. 40-504 Short........................................................ 40-562
Failure code [DW43KB] Travel Speed Sol Failure code [DY2EKB] Wiper Drive (Rev)
Short Circuit ............................................. 40-506 Short........................................................ 40-564
Failure code [DW45KA] swing holding brake Failure code [879BKA] A/C Outer sensor Open
Sol Open Circuit........................................ 40-508 Circuit ........................................................ 80-56
Failure code [DW45KB] Swing Brake Sol Short Failure code [879BKB] A/C Outer sensor Short
Circuit ...................................................... 40-511 Circuit ........................................................ 80-58
Failure code [DW91KA] Travel Junction Sol Failure code [879DKZ] Sunlight sensor Open
Open Circuit ............................................. 40-514 or Short Circuit............................................ 80-62
Failure code [DW91KB] Travel Junction Sol Failure code [879GKX] Refrigerant
Short Circuit ............................................. 40-516 Abnormality ................................................ 80-66
Failure code [DWA2KA] Attachment Sol Open Failure code list related to air conditioner ........ 80-53
Circuit ...................................................... 40-518 Failure codes table ..................................... 40-112
Failure code [DWA2KB] Attachment Sol Short Final drive ............................................10-34, 60-8
Circuit ...................................................... 40-520 Fuse location table...................................... 40-105
Failure code [DWK0KA] 2-stage Relief Sol
Open Circuit ............................................. 40-522
Failure code [DWK0KB] 2-stage Relief Sol
H
Short Circuit ............................................. 40-524 H-1 All of work equipment, swing and travel
Failure code [DWK2KA] Variable Back operation lacks speed or power .................. 40-653
Pressure Sol Open Circuit.......................... 40-526 H-2 Engine speed lowers significantly or
Failure code [DWK2KB] Variable Back engine stalls ............................................. 40-657
Pressure Sol Short Circuit.......................... 40-528 H-3 Any of work equipment, swing and travel
Failure code [DWK8KA] Swing C/O Solenoid does not work ........................................... 40-660
Open Circuit ............................................. 40-530 H-4 Unusual sound is heard from around
Failure code [DWK8KB] Swing C/O Solenoid hydraulic pump ......................................... 40-661
Short Circuit ............................................. 40-532 H-5 Fine control performance or response is
Failure code [DXA8KA] PC-EPC (F) Sol Open poor ......................................................... 40-662
Circuit ...................................................... 40-534 H-6 Speed or power of boom is low .............. 40-664
Failure code [DXA8KB] PC-EPC (F) Sol Short H-7 Speed or power of arm is low................. 40-668
Circuit ...................................................... 40-536 H-8 Speed or power of bucket is low............. 40-673
Failure code [DXA9KA] PC-EPC (R) Sol Open H-9 Work equipment does not move in single
Circuit ...................................................... 40-538 operation.................................................. 40-677
Failure code [DXA9KB] PC-EPC (R) Sol Short H-10 Hydraulic drift of boom is large ............. 40-678
Circuit ...................................................... 40-540 H-11 Hydraulic drift of arm is large ................ 40-679
Failure code [DXE0KA] LS-EPC Sol Open H-12 Hydraulic drift of bucket is large............ 40-681
Circuit ...................................................... 40-542 H-13 Time lag of work equipment is large...... 40-682
Failure code [DXE0KB] LS-EPC Sol Short H-14 When part of work equipment is relieved
Circuit ...................................................... 40-544 singly, other parts of work equipment move . 40-684
Failure code [DXE4KA] Service Current EPC H-15 One-touch power maximizing function
Disc. ........................................................ 40-546 does not work ........................................... 40-685
Failure code [DXE4KB] Service Current EPC H-16 Machine push up function does not work ....40-
S/C .......................................................... 40-547 686
Failure code [DXE5KA] Merge-divider Main Sol H-17 In combined operation of work
Open Circuit ............................................. 40-548 equipment, equipment having heavier load
Failure code [DXE5KB] Merge-divider Main Sol moves slower ........................................... 40-687
Short Circuit ............................................. 40-550 H-18 In combined operations of swing and
boom RAISE, boom rising speed is low....... 40-688
6 PC360LC-10
INDEX
H-19 In combined operations of swing and Information contained in troubleshooting table

travel, travel speed drops largely ................ 40-689 (S mode) .................................................. 40-713
H-20 Machine does not travel straight........... 40-690 Information described in troubleshooting table
H-21 Travel speed is too low........................ 40-693 (H-mode).................................................. 40-647
H-22 Machine is hard to steer or travel power Information in troubleshooting table ...... 40-47, 80-52
is low ....................................................... 40-695 Inspection procedure before troubleshooting... 40-15
H-23 Travel speed does not change, or travel Isolating the parts causing hydraulic drift in
speed is too low or high ............................. 40-698 work equipment .......................................... 30-84
H-24 One of tracks does not run (on one side
alone) ...................................................... 40-699
H-25 Upper structure does not swing in both
K
right and left directions............................... 40-701 KCCV layout drawing .................................... 10-19
H-26 Upper structure does not swing in only KCCV ventilator............................................ 10-22
one direction............................................. 40-702 KDPF .......................................................... 10-24
H-27 Swing acceleration or swing speed is low KOMTRAX system ..................................... 10-259
in both directions (right and left).................. 40-703 KVGT ............................................................ 10-5
H-28 Swing acceleration performance is poor
or swing speed is slow in only one direction. 40-704
H-29 Upper structure overruns remarkably
L
when it stops swinging in both directions (right Layout of air conditioner related parts and
and left).................................................... 40-705 connectors ................................................. 80-32
H-30 Upper structure overruns excessively List of abbreviation........................................ 00-55
when it stops swinging in only one direction. 40-706 List of Failure Mode and Cause.................... 40-648
H-31 Shock is large when upper structure
stops swinging .......................................... 40-707
H-32 Large unusual noise is heard when upper
M
structure stops swinging ............................ 40-708 Machine monitor system.............................. 10-240
H-33 When swing holding brake is applied, Main pump ......................................... 10-49, 60-23
hydraulic drift of swing is large.................... 40-709 Method of disconnecting and connecting of
H-34 When swing holding brake is released, push-pull type coupler ................................. 00-29
hydraulic drift of swing is large.................... 40-710
H-35 When additional attachment is installed,
attachment circuit is not switched ............... 40-711 O
H-36 Oil flow in attachment circuit cannot be Outer temperature sensor.............................. 80-23
controlled ................................................. 40-712 Outline of refrigeration cycle ............................ 80-8
Handling battery disconnect switch .............. 30-164
Handling cylinder cutout mode operation ........ 30-46
Handling equipment of fuel system devices..... 00-25 P
Handling no injection cranking operation......... 30-47 Parts and connectors layout .......................... 80-31
Handling of compressor oil ............................ 80-83 PC valve ...................................................... 10-61
Handling of electrical equipment .................... 00-32 Pm clinic service......................................... 30-166
Handling of hydraulic equipment .................... 00-27 Power train................................................... 10-30
Handling of intake system parts ..................... 00-26 PPC valve........................................ 10-156, 60-39
Handling voltage circuit of engine controller .. 30-163 Practical use of KOMTRAX............................ 00-48
How to open the electrical system abnormality Precautions for disconnecting and connecting
record screen in service mode of the machine air conditioner piping ................................... 80-81
monitor....................................................... 80-39 Precautions for KDPF (KCSF and KDOC)
How to read electric wire code ....................... 00-40 Cleaning and Replacement........................ 40-109
How to read the shop manual ........................ 00-21 Precautions for refrigerant ............................... 80-3
How to read this manual .................................. 50-4 Precautions when performing operation.......... 00-43
Hydraulic circuit diagram ................................. 90-7 Preparation of dummy temperature sensor (for
Hydraulic component layout........................... 10-38 KDOC and KDPF temperature sensors)...... 40-107
Hydraulic tank .................................... 10-42, 60-22 Preparation of short circuit electrical connector
(for failure codes [CA1883] and [CA3135]) .. 40-108
I Preparation work for troubleshooting of
electrical system ......................................... 40-34
Idler ............................................................. 60-14 Procedure for testing and troubleshooting ....... 80-24
Important safety notice .................................. 00-14
PC360LC-10 7
INDEX
R Removal and installation of pump controller

assembly.................................................. 50-249
Receiver drier............................................... 80-21
Removal and installation of pump swash plate
Releasing remaining pressure from hydraulic
sensor...................................................... 50-254
circuit ......................................................... 30-53
Removal and installation of radiator assembly . 50-66
Removal and installation of air conditioner
Removal and installation of revolving frame
compressor assembly ............................... 50-122
assembly.................................................. 50-161
Removal and installation of air conditioner
Removal and installation of seat belt............. 50-237
condenser assembly ................................. 50-124
Removal and installation of sprocket ............ 50-149
Removal and installation of air conditioner unit
Removal and installation of supply pump
assembly.................................................. 50-231
assembly.................................................... 50-18
Removal and installation of arm assembly .... 50-193
Removal and installation of swing circle
Removal and installation of bucket assembly 50-192
assembly.................................................. 50-145
Removal and installation of center swivel joint
Removal and installation of swing motor and
assembly.................................................. 50-167
swing machinery assembly ........................ 50-136
Removal and installation of control valve
Removal and installation of travel motor and
assembly.................................................. 50-177
final drive assembly................................... 50-126
Removal and installation of counterweight
Removal and installation of work equipment
assembly.................................................. 50-163
assembly.................................................. 50-195
Removal and installation of cylinder head
Replacing alternator belt................................ 30-50
assembly.................................................... 50-44
Replacing fan belt ......................................... 30-49
Removal and installation of engine and main
ROPS cab.................................................. 10-191
pump assembly .......................................... 50-73
Removal and installation of engine controller
assembly.................................................. 50-246 S
Removal and installation of engine front seal... 50-85
S-1 Engine does not crank when starting
Removal and installation of engine hood
switch is turned to START position.............. 40-714
assembly.................................................... 50-99
S-2 The engine cranks but exhaust smoke
Removal and installation of engine rear seal ... 50-90
does not come out..................................... 40-715
Removal and installation of floor frame
S-3 Fuel is being injected but engine does not
assembly.................................................. 50-225
start (incomplete combustion: engine cranks
Removal and installation of front window
but does not start) ..................................... 40-716
assembly.................................................. 50-219
S-4 Startability is poor ................................. 40-717
Removal and installation of front wiper
S-5 Engine does not pick up smoothly .......... 40-719
assembly.................................................. 50-239
S-6 Engine stops during operation................ 40-721
Removal and installation of fuel tank assembly....50-
S-7 Engine runs rough or is unstable ............ 40-723
97
S-8 Engine lacks power............................... 40-724
Removal and installation of hydraulic oil cooler
S-9 KDPF gets clogged in a short time.......... 40-726
assembly.................................................... 50-69
S-10 Engine oil consumption is excessive..... 40-728
Removal and installation of hydraulic tank
S-11 Engine oil becomes contaminated early 40-729
assembly.................................................. 50-170
S-12 Fuel consumption is excessive............. 40-730
Removal and installation of idler and idler
S-13 Oil is in coolant (or coolant spurts or
cushion assembly ..................................... 50-150
coolant level goes down) ........................... 40-731
Removal and installation of injector assembly . 50-28
S-14 Oil pressure drops............................... 40-732
Removal and installation of KCCV assembly . 50-118
S-15 Fuel mixes into engine oil .................... 40-733
Removal and installation of KDPF assembly . 50-102
S-16 Water mixes into engine oil (milky)........ 40-734
Removal and installation of KOMTRAX
S-17 Coolant temperature rises too high
terminal assembly ..................................... 50-256
(overheating) ............................................ 40-735
Removal and installation of machine monitor
S-18 Unusual noise is heard ........................ 40-736
assembly.................................................. 50-252
S-19 Vibration is excessive.......................... 40-737
Removal and installation of main pump
S-20 Air cannot be bled from fuel circuit ........ 40-738
assembly.................................................. 50-173
S-21 Frequent active regeneration ............... 40-739
Removal and installation of mass air flow and
S-22 Active regeneration takes time ............. 40-740
temperature sensor ................................... 50-255
S-23 White smoke is exhausted during active
Removal and installation of operator cab glass
regeneration ............................................. 40-741
(adhered glass)......................................... 50-209
Sensor....................................................... 10-262
Removal and installation of operator's cab
Separation and connection of track shoe
assembly.................................................. 50-204
assembly.................................................. 50-146
Sequence of events in troubleshooting ........... 40-11
8 PC360LC-10
INDEX
Sketch of tools for testing and adjusting ............ 30-7 Track frame and idler cushion .............. 10-36, 60-12
Sketches of special tools ............................... 50-15 Track roller ................................................... 60-16
Solenoid valve.................................. 10-177, 60-50 Track shoe ................................................... 60-19
Special functions of machine monitor.............. 30-95 Travel motor ............................................... 10-141
Special tools list............................................ 50-10 Travel PPC valve .............................. 10-163, 60-42
Specification drawing ...................................... 01-3 Troubleshooting chart 1................................. 80-48
Specifications ................................................. 01-5 Troubleshooting chart 2................................. 80-49
Sprocket ...................................................... 60-10 Troubleshooting method for open circuit in
Standard tightening torque table .................... 00-49 wiring harness of pressure sensor system ..... 40-49
Standard value table for engine related parts..... 20-3 Troubleshooting points .................................... 40-9
Standard value table for machine ..................... 20-5 Troubleshooting with gauge pressure ............. 80-76
Sunlight sensor............................................. 80-22
Swing circle..........................................10-31, 60-5
Swing machinery ..................................10-32, 60-6
V
Swing motor ..................................... 10-130, 60-34 Valve control ................................................ 10-40
Symbols in electric circuit diagram.................... 90-9
Symbols in hydraulic circuit diagram................. 90-3
Symptom and troubleshooting numbers.......... 40-44
W
System component parts............................. 10-227 Weight table ................................................... 01-8
System diagram ........................................... 80-28 Work equipment ............................... 10-187, 60-53
Work equipment and swing PPC valve ......... 10-156
Work equipment shims................................ 10-188
T Working range drawings.................................. 01-4
T-branch box and T-branch adapter table...... 40-100
Table of fuel, coolant and lubricants ................ 01-10
Testing air leakage (duct)............................... 80-35
Testing and adjusting oil pressure in pump LS
control circuit .............................................. 30-67
Testing and adjusting oil pressure in pump PC
control circuit .............................................. 30-62
Testing and adjusting oil pressure in work
equipment, swing, and travel circuits............. 30-54
Testing and adjusting track tension................. 30-52
Testing and adjusting valve clearance ............ 30-15
Testing blowby pressure ................................ 30-27
Testing boost pressure .................................. 30-10
Testing compression pressure ....................... 30-19
Testing diodes ............................................ 30-165
Testing (dual) pressure switch for refrigerant ... 80-45
Testing EGR valve and KVGT oil pressures..... 30-30
Testing engine oil pressure ............................ 30-29
Testing engine speed ...................................... 30-9
Testing exhaust gas color .............................. 30-13
Testing FRESH/RECIRC air changeover ........ 80-43
Testing fuel circuit for leakage ........................ 30-45
Testing fuel discharge, return and leakage ...... 30-38
Testing fuel pressure ..................................... 30-31
Testing in accordance with testing procedure .. 40-16
Testing oil leakage ........................................ 30-86
Testing oil pressure of control circuit ............... 30-60
Testing outlet pressure of solenoid valve......... 30-76
Testing PPC valve output pressure................. 30-80
Testing pump swash plate sensor................... 30-83
Testing relays ............................................... 80-47
Testing sunlight sensor.................................. 80-44
Testing swing circle bearing clearance............ 30-51
Testing vent (mode) changeover .................... 80-41
Testing with self-diagnosis function................. 80-38
Tools for testing and adjusting.......................... 30-3
PC360LC-10 9
PC360LC-10 HYDRAULIC EXCAVATOR
Form No. SEN05619-03
©2013 KOMATSU
All Rights Reserved
Printed in Japan 03–13

Komatsu - pc360lc 10.he - Sm.sen05619 03.Jp - Ocrbmd

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SEN05619-03

HYDRAULIC PC360LC -10

PC360LC-10 70001 and up

00 Index and foreword

Center swivel joint ............................................................................................................ 10-184

Adjusting mirrors ................................................................................................................ 30-92

Failure code [D862KA] GPS Antenna Open Circuit ............................................................. 40-404

Failure code [DXA8KA] PC-EPC (F) Sol Open Circuit.......................................................... 40-534

Removal and installation of KDPF assembly....................................................................... 50-102

Swing machinery ................................................................................................................. 60-6

Foreword, safety and general information (ALL-0370-001-A-00-A)

Important safety notice (ALL-1120-012-A-01-A)

General precautions knowledge of welding perform the work. When

k Slinging with one rope may cause turning

Precautions for using mobile crane

Precautions for using overhead traveling crane

• Before starting work, check the wire ropes, Nominal

Manufacturer Part name

For tightening torques, see "Others",

Fire prevention (ALL-0000-001-K-27-A)

Action if fire occurs (ALL-0000-17A-K-01-A)

KDPF is a system for purifying soot in exhaust

To prevent pollution, pay full attention to the way to

Some kinds of rubber and plastics may produce

How to read the shop manual (ALL-0320-010-A-01-A)

Composition of shop manual

Explanation of terms for maintenance standard (ALL-0330-006-A-01-A)

the parts can not be used any longer. This value

Handling equipment of fuel system devices (PC-AD00-2A4-K-00-A)

Use care for working environment

How to clean parts when dirt is stuck

Precautions for replacing fuel filter cartridge

Handling of intake system parts (PC220-A900-2A4-K-00-A)

Be careful of working environment

Handling of hydraulic equipment (ALL-C000-2A4-P-01-A)

Be careful of working environment

Disassembly and maintenance work in the field

Plugging of opening (prevention of flowing out

Method of disconnecting and connecting of push-pull type coupler (ALL-

Handling of electrical equipment (ALL-E000-2A4-P-01-A)

Precautions for handling electric equipment

Handling wiring harnesses and connectors

Main failures occurring in wiring harness

blow it with compressed air and spray it with

High-pressure water entering connector

Entry of water, mud or dirt when disconnecting a

• Check that there is no oil, dirt or water stick

3. Action to take after removing connectors

• If the connector clamp is removed, be sure to Drying wiring harness

2. Dry the inside of the connector with a dryer.

3. Perform a continuity test on the connector.

2. While pressing lock (L2), pull out connector (1).

Slide, lock type

a If the lock is located on the underside, use

temperature even for a short period of time.

• Precautions when performing arc welding

Precautions for troubleshooting electrical